Actuator and robot arm apparatus

ABSTRACT

An actuator including a reduction gear that reduces, by a certain reduction ratio, a rotational velocity of an input shaft joined to a rotary shaft of a motor, and transmits the reduced rotational velocity to an output shaft, a first absolute angle encoder that detects a rotational angle of the input shaft, and a second absolute angle encoder that detects a rotational angle of the output shaft.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application of U.S. patent application Ser. No. 15/121,602, filed Aug. 25, 2016, which is a National Stage Entry of PCT/JP2015/054675, filed Feb. 19, 2015, which claims priority from prior Japanese Priority Patent Application 2014-044134 filed in the Japan Patent Office on Mar. 6, 2014. Each of the above-referenced applications is hereby incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to an actuator and a robot arm apparatus.

BACKGROUND ART

Rotary encoders (hereinafter also simply called encoders) are widely used as sensor devices for detecting the rotational angle of a rotationally driven member, such as power steering in an automobile, or the joint units of a robot apparatus. In the detection of a rotational angle using an encoder, various technologies have been proposed to further improve the detection accuracy.

For example, Patent Literature 1 discloses technology that converts the rotation of a primary rotary shaft into the rotations of two detection shafts by reduction gears with different reduction ratios, detects the rotational angle of each of the detection shafts with respective encoders, and computes an absolute angle of the primary rotary shaft based on the difference between the detected rotational angles, thereby accurately detecting the rotational angle of the primary rotary shaft. As another example, Patent Literature 2 discloses technology configured so that a relative angle encoder is disposed on the input shaft of a reduction gear joined to the rotary shaft of a motor, and an absolute angle encoder is disposed on the output shaft of the reduction gear. With this configuration, the relationship regarding the error that may be produced between the detection value of the relative angle encoder and the detection value of the absolute angle encoder is acquired in advance, and this relationship regarding the error is used to correct the detection result of the absolute angle encoder.

CITATION LIST Patent Literature

Patent Literature 1: JP 2007-78552A

Patent Literature 2: JP 2008-148412A

SUMMARY OF INVENTION Technical Problem

However, with the technology described in Patent Literature 1, it is necessary to provide two reduction gears with respect to the motor, and to provide respective encoders on the output shafts of each of the reduction gears. Thus, there is a possibility that the configuration may become bulkier. Also, with the technology described in Patent Literature 2, the relationship regarding the error discussed above is acquired as the error of the detection value of the absolute angle encoder with respect to the detection of the relative angle encoder, under the assumption that the detection value of the relative angle encoder is a reliable value. Consequently, if the detection accuracy of the relative angle encoder is low, the accuracy of the final detection result of the rotational angle of the motor likewise will not improve, and thus this configuration is not necessarily appropriate for ensuring high detection accuracy.

Furthermore, in devices such as a robot apparatus used for medical use and the power steering discussed above, for example, high safety is demanded for the driving of these devices. In the technologies described in Patent Literature 1 and 2 above, such a safety perspective is not examined adequately. Accordingly, the present disclosure proposes a new and improved actuator and robot arm apparatus capable of accurately detecting a rotational angle and also driving more safely.

Solution to Problem

According to the present disclosure, there is provided an actuator including: a reduction gear that reduces, by a certain reduction ratio, a rotational velocity of an input shaft joined to a rotary shaft of a motor, and transmits the reduced rotational velocity to an output shaft; a first absolute angle encoder that detects a rotational angle of the input shaft; and a second absolute angle encoder that detects a rotational angle of the output shaft.

According to the present disclosure, there is provided a robot arm apparatus including: an arm unit made up of a plurality of links joined by one or a plurality of a joint unit; and a driving control unit that controls driving of an actuator provided in at least one of the joint unit based on a state of the joint unit. The actuator includes a reduction gear that reduces, by a certain reduction ratio, a rotational velocity of an input shaft joined to a rotary shaft of a motor, and transmits the reduced rotational velocity to an output shaft, a first absolute angle encoder that detects a rotational angle of the input shaft, and a second absolute angle encoder that detects a rotational angle of the output shaft.

According to the present disclosure, absolute angle encoders are provided on both the input shaft and the output shaft with an interposed reduction gear. By interposing the reduction gear, it becomes possible to detect the rotational angle of the output shaft at high resolution. Additionally, since the rotational angle may be detected immediately at power-on, movement that is unexpected to the user as part of initialization operations may be prevented.

Advantageous Effects of Invention

According to the present disclosure as described above, it is possible to detect a rotational angle accurately and also to drive more safely. Note that the effects described above are not necessarily limited, and along with or instead of the effects, any effect that is desired to be introduced in the present specification or other effects that can be expected from the present specification may be exhibited.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an exploded perspective view illustrating an overall configuration of an actuator according to the present embodiment.

FIG. 2 is a schematic diagram illustrating one example configuration of an encoder according to the present embodiment.

FIG. 3 is an explanatory diagram for explaining the principle of angle detection by an encoder according to the present embodiment.

FIG. 4 is a function block diagram illustrating a schematic configuration of a rotational angle detection system according to the present embodiment.

FIG. 5 is an explanatory diagram for describing a process of computing a cumulative operation angle of an input shaft while accounting for error of the input shaft, which is conducted in a rotational angle detection method according to the present embodiment.

FIG. 6 is a flowchart illustrating an example of a processing procedure of a rotational angle detection method according to the present embodiment.

FIG. 7 is an explanatory diagram for describing an application example of using a robot arm apparatus according to an embodiment of the present disclosure for a medical purpose.

FIG. 8 is a schematic diagram illustrating an external appearance of a robot arm apparatus according to an embodiment of the present disclosure.

FIG. 9A is a schematic diagram illustrating one example configuration of a torque sensor applied to an actuator according to the present embodiment.

FIG. 9B is a schematic diagram illustrating another example configuration of a torque sensor applied to an actuator according to the present embodiment.

FIG. 10 is an explanatory diagram for describing ideal joint control according to an embodiment of the present disclosure.

FIG. 11 is a functional block diagram illustrating an exemplary configuration of a robot arm control system according to an embodiment of the present disclosure.

FIG. 12 is an explanatory diagram for describing a pivot movement that is a specific example of an arm movement according to an embodiment of the present disclosure.

FIG. 13 is an explanatory diagram for describing a purpose of motion and a constraint condition for implementing the pivot movement illustrated in FIG. 12.

FIG. 14 is a schematic diagram illustrating an external appearance of a modified example having a redundant degree of freedom in a robot arm apparatus according to an embodiment of the present disclosure.

FIG. 15 is a flowchart illustrating a processing procedure of a robot arm control method according to an embodiment of the present disclosure.

FIG. 16 is a functional block diagram illustrating an exemplary configuration of a hardware configuration of a robot arm apparatus and a control device according to an embodiment of the present disclosure.

DESCRIPTION OF EMBODIMENT(S)

Hereinafter, (a) preferred embodiment(s) of the present disclosure will be described in detail with reference to the appended drawings. In this specification and the drawings, elements that have substantially the same function and structure are denoted with the same reference signs, and repeated explanation is omitted.

Hereinafter, the description will proceed in the following order.

-   1. Configuration of actuator -   1-1. Overall configuration -   1-2. Configuration of encoder -   2. Configuration of rotational angle detection system -   3. Processing procedure of rotational angle detection method -   4. Malfunction detection -   5. Application to robot arm apparatus for medical use -   6. Application example -   6-1. Review of medical robot arm apparatus -   6-2. Embodiment of present disclosure -   6-2-1. External appearance of robot arm apparatus -   6-2-2. Generalized inverse dynamics -   6-2-2-1. Virtual force calculating process -   6-2-2-1. Actual force calculating process -   6-2-3. Ideal joint control -   6-2-4. Configuration of robot arm control system -   6-2-5. Specific example of purpose of motion -   6-3. Processing procedure of robot arm control method -   6-4. Hardware configuration -   6-5. Summary of medical robot arm apparatus -   7. Supplement

1. Configuration of Actuator

First, a configuration of an actuator according to an embodiment of the present disclosure will be described. In the following, first, an overall configuration of the actuator according to the present embodiment will be described in (1-1. Overall configuration). Next, one example configuration of an absolute angle encoder installed onboard the actuator according to the present embodiment will be described in (1-2. Configuration of encoder). Note that the following describes an embodiment of the present disclosure by taking, as an example, a case in which an actuator according to the present disclosure is applied to a joint unit of a robot arm. However, the target to which an actuator according to the present disclosure may be applied is not limited to such an example, and the actuator may also be applied favorably to devices in which accurate angle detection is demanded from a safety perspective, such as motorized surgical instruments used in surgeries, power steering for automobiles, and motorized playground equipment installed in amusement parks or the like. In addition, an actuator according to the present disclosure may also be applied to devices in which accurate angle detection is demanded from an operability perspective, such as controllers used in games or simulations that imitate the steering wheel of an automobile, for example.

(1-1. Overall Configuration)

First, an overall configuration of an actuator according to the present embodiment will be described with reference to FIG. 1. FIG. 1 is an exploded perspective view illustrating an overall configuration of an actuator according to the present embodiment.

Referring to FIG. 1, the actuator 300 according to the present embodiment is equipped with a motor 310, a reduction gear 320, two rotary encoders 330 and 340 (encoders 330 and 340), an output shaft 350, and a housing 360. In the actuator 300, the rotation of the rotary shaft of the motor 310 is reduced by the reduction gear 320 at a certain reduction ratio, and transmitted to other downstream members via the output shaft 350. As a result, the other members are driven. In addition, the encoders 330 and 340 detect the rotational angle of the rotary shaft of the motor 310 and the rotational angle of the rotary shaft of the output shaft 350, respectively.

Herein, since the rotational angle of the motor 310 is also the rotational angle at the input shaft of the reduction gear 320, in the following description, the rotational angle and the rotational velocity of the motor 310 are also called the rotational angle and the rotational velocity of the input shaft, respectively. Additionally, the rotational angle and the rotational velocity of the rotary shaft on the output shaft 350 are also called the rotational angle and the rotational velocity of the output shaft. The present embodiment, by disposing absolute angle encoders on both the input shaft and the output shaft with the reduction gear 320 interposed, accurately detects the rotational angle of the output shaft and also satisfies various requisites demanded for safety.

The motor 310 is a driving mechanism that, when given a certain control value (current value), causes a rotary shaft to rotate at a rotational velocity corresponding to the control value, and thereby produces driving force. In the present embodiment, a brushless motor is used as the motor 310. Generally, a motor needs to switch the orientation of current flowing through a coil according to the rotation of a rotor provided internally, and thereby vary the direction of a magnetic field. In a brushless motor, this switching of the orientation of current is not conducted mechanically using a brush, but rather conducted electrically using a component such as a semiconductor switch instead of a brush.

The reduction gear 320 is joined to the output shaft of the motor 310. The reduction gear 320 reduces by a certain reduction ratio the rotational velocity of the rotary shaft of the joined motor 310 (in other words, the rotational velocity of the input shaft), and transmits to the output shaft 350. In the present embodiment, the configuration of the reduction gear 320 is not limited to a specific configuration, and various known types of reduction gears may be used as the reduction gear 320. However, for the reduction gear 320, it is preferable to use one capable of accurately setting the reduction ratio, such as a Harmonic Drive (registered trademark), for example. The specific configuration of the reduction gear 320 may be designed appropriately according to the configuration of the actuator 300, so that a desired rotational velocity and torque are transmitted to members connected downstream of the output shaft 350.

The encoder 330 detects the rotational angle of the input shaft (that is, the rotational angle of the motor 310). In the present embodiment, the encoder 330 is an absolute angle encoder, and is able to detect the absolute angular position of the input shaft. Hereinafter, the encoder 330 is also referred to as the input shaft encoder 330 or the absolute angle encoder 330. The specific configuration of the encoder 330 is described in (1-2. Configuration of encoder) below, and for this reason a detailed description is omitted at this point. However, in the present embodiment, it is sufficient for the encoder 330 to be an absolute angle encoder, and the configuration is not limited to the configuration described in (1-2. Configuration of encoder) below, but rather is arbitrary.

Herein, since the motor 310 is a brushless motor as discussed above, switching the orientation of the current requires a sensor that detects the rotation of the rotor (for example, a Hall effect sensor for motor driving). Since the rotation of the rotor corresponds to the rotation of the input shaft, in the present embodiment, the encoder 330 provided on the input shaft is able to fulfill the additional function of such a Hall effect sensor for motor driving. In this way, in the present embodiment, the motor 310 may be driven based on the rotational angle of the input shaft detected by the encoder 330, and a Hall effect sensor for motor driving may also not be provided. Consequently, since the components may be decreased, a more compact and lower-cost actuator 300 may be realized.

In addition, by providing the encoder 330 on the input shaft, it becomes possible to detect the rotational angle of the output shaft accurately to the extent of the interposed reduction ratio of the reduction gear 320. For example, if the reduction ratio is 1:100, when the rotational angle of the input shaft is detected from 0 (degrees) to 360 (degrees), the rotational angle of the output shaft varies from 0 (degrees) to 3.6 (degrees). In other words, detecting the rotational angle of the input shaft corresponds to detecting the rotational angle of the output shaft enlarged by a ratio equal to the reduction ratio. Consequently, by detecting the rotational angle of the output shaft based on the detection value of the rotational angle of the input shaft by the encoder 330, the rotational angle of the output shaft may be detected at high resolution. Note that a specific method of detecting the rotational angle of the output shaft based on the detection value of the rotational angle of the input shaft in this way is described in detail in <2. Configuration of rotational angle detection system> below.

The encoder 340 detects the rotational angle of the output shaft. In the present embodiment, the encoder 340 is an absolute angle encoder, and is able to detect the absolute angular position of the output shaft. Hereinafter, the encoder 340 is also referred to as the output shaft encoder 340 or the absolute angle encoder 340. Note that the encoder 340 may have a similar configuration to the encoder 330. For example, the configuration described in (1-2. Configuration of encoder) below may be applied favorably as the encoder 340. However, the present embodiment is not limited to such an example. It is sufficient for the encoder 340 to be an absolute angle encoder, and the configuration is arbitrary.

The housing 360 has an approximately cylindrical shape, in which the respective components are housed internally. By being housed inside the housing 360, the respective components are assembled as an actuator that drives each part attendant on rotational driving, such as the joint units of the robot arm apparatus described in <6. Application example> below.

The above thus describes an overall configuration of the actuator 300 according to the present embodiment with reference to FIG. 1. Note that the actuator 300 additionally may be provided with other configuration elements besides the illustrated configuration elements. For example, the actuator 300 additionally may be provided with any types of members that may be included in a typical actuator, such as a driver circuit (driver integrated circuit (IC)) that induces rotational driving in the motor 310 by supplying a current to the motor 310, or a torque sensor that detects torque in the output shaft 350 (in other words, the output torque (generated torque) of the actuator 300).

(1-2. Configuration of Encoder)

Next, one example configuration of the encoders 330 and 340 will be described with reference to FIGS. 2 and 3. FIG. 2 is a schematic diagram illustrating one example configuration of the encoders 330 and 340 according to the present embodiment. FIG. 3 is an explanatory diagram for explaining the principle of angle detection by the encoders 330 and 340 according to the present embodiment.

As illustrated in FIG. 2, each of the encoders 330 and 340 is a magnetic encoder realized by combining a magnet 331 that has been magnetized with two poles, and two Hall effect sensors 332 and 333. The magnet 331 is approximately ring-shaped, and given polarity so that one end of the ring shape is an N pole and another end is an S pole. The Hall effect sensors 332 and 333 are provided respectively on the perimeter of the magnet 331, at positions rotated 90 (degrees) with respect to rotation about the center axis of the ring shape of the magnet 331.

The magnet 331 is connected so that the center axis of the ring shape serves as a rotary shaft, so as to rotate together with a rotary shaft to be detected (in the present embodiment, the input shaft or the output shaft). The rotation of the magnet 331 causes the magnetic field detected by the Hall effect sensors 332 and 333 to vary periodically.

In FIG. 3, the rotational angle θ of the magnet 331 (that is, the rotational angle θ of the rotary shaft to be detected) is taken to be the horizontal axis, the outputs of the Hall effect sensors 332 and 333 are taken to be the vertical axis, and the relationship between the two is plotted. Herein, since the Hall effect sensors 332 and 333 are disposed at positions rotated 90 (degrees) on the perimeter of the magnet 331, the outputs of Hall effect sensors 332 and 333 yield waveforms that are phase-shifted by 90 (degrees), as illustrated in FIG. 3. In other words, a sine curve (sin θ) is acquired by one Hall effect sensor 332, while a cosine curve (cos θ) is acquired by the other Hall effect sensor 333. Consequently, the rotational angle θ may be computed from the outputs of the Hall effect sensors 332 and 333 by the following Math. 1.

$\begin{matrix} \left\lbrack {{Math}.\mspace{14mu} 1} \right\rbrack & \; \\ {\theta = {\arctan\left( \frac{\sin\;\theta}{\cos\;\theta} \right)}} & (1) \end{matrix}$

For example, provided that the normalized output from the Hall effect sensor 332 is 1 (this corresponds to sin θ=1), and the normalized output from the Hall effect sensor 333 is 0 (this corresponds to cos θ=0), the above Math. 1 gives θ=arctan(1/0)≈∞≈90 (degrees).

In this way, in each of the encoders 330 and 340, the rotational angle of the magnet 331 (that is, the rotational angle of the rotary shaft to be detected) may be determined uniquely over a range from 0 (degrees) to 360 (degrees) according to the outputs from the two Hall effect sensors 332 and 333. Consequently, even in the instant that the power source is cut off and restarted, by detecting the outputs from the Hall effect sensors 332 and 333 on startup, it is possible to detect the rotational angle of the rotary shaft immediately.

The above thus describes one example configuration of the encoders 330 and 340 with reference to FIGS. 2 and 3. However, in the present embodiment, the configuration of the encoders 330 and 340 is not limited to such an example, and various types of encoders may be applied insofar as the encoders are absolute angle encoders. However, absolute angle encoders including a magnet 331 and Hall effect sensors 332 and 333 as illustrated in FIG. 2 have a comparatively simple configuration, and thus may be miniaturized, and are also superior from a cost point of view. Consequently, by using absolute angle encoders having the configuration illustrated as an example in FIG. 2 as the encoders 330 and 340, the actuator 300 may be configured more compactly and more cheaply. However, on the other hand, the absolute angle encoders having the configuration illustrated as an example in FIG. 2 are known to have an angle detection accuracy that is not very high. In the present embodiment, as discussed earlier, by disposing the encoders 330 and 340 on both the input shaft and the output shaft, and detecting the rotational angle of the output shaft based on the detection value of the rotational angle of the input shaft from the encoder 330, it becomes possible to detect the rotational angle of the output shaft accurately, even in the case of using cheap absolute angle encoders like the one illustrated as an example in FIG. 2.

2. Configuration of Rotational Angle Detection System

Next, a schematic configuration of a rotational angle detection system according to the present embodiment will be described with reference to FIG. 4. FIG. 4 is a function block diagram illustrating a schematic configuration of a rotational angle detection system according to the present embodiment. In the present embodiment, the rotational angle of the output shaft may be detected accurately with the configuration illustrated as an example in FIG. 4.

Referring to FIG. 4, the rotational angle detection system 3 according to the present embodiment is equipped with an actuator 300, and a control unit 370 that performs a certain process based on the detection values of the encoders 330 and 340 of the actuator 300. The control unit 370 is made up of any of various types of processors such as a central processing unit (CPU), for example, and a certain process may be executed as a result of the control unit 370 operating in accordance with a certain program. In the present embodiment, the control unit 370 is able to compute the rotational angle of the output shaft based on the detection value of the rotational angle of the input shaft from the encoder 330. Note that the control unit 370 may also perform other processes, such as a process of detecting a failure in the actuator 300 as described in <4. Failure detection> below, for example. The control unit 370 may be integrated with the actuator 300, or be provided as a separate member from the actuator 300 and conduct various processes based on various information transmitted from the actuator 300.

In FIG. 4, for the sake of explanation, part of the configuration of the actuator 300 is illustrated schematically. Since the input shaft encoder 330, the brushless motor 310, the reduction gear 320, and the output shaft encoder 340 illustrated in the drawing correspond to the encoder 330, the motor 310, the reduction gear 320, and the encoder 340 illustrated in FIG. 1, detailed description will be omitted at this point.

Functionally, the control unit 370 includes an output shaft angle information acquisition unit 371, a motor cumulative rotation count computation unit 372, an input shaft angle information acquisition unit 373, an input shaft cumulative operation angle computation unit 374, and an output shaft angle computation unit 375. Note that the following description of the control unit 370 takes specific numerical values as an example for easier comprehension. Specifically, the functions of the control unit 370 are described for a case in which, as an example, the reduction ratio of the reduction gear 320 is 1:100, the detection value of the input shaft encoder 330 is 181 (degrees), and the detection value of the output shaft encoder 340 is 19.6 (degrees). However, these numerical values are merely an example, and in the present embodiment, the rotational angle of the output shaft may be computed according to a similar process, even in cases where the reduction ratio of the reduction gear 320 and the detection values in each of the encoders 330 and 340 are other values.

In addition, the following description supposes a case in which the actuator 300 according to the present embodiment is applied to a joint unit provided in an arm unit of a robot arm apparatus, for example, and assumes that the output shaft of the actuator 300 rotates within a range from 0 (degrees) to 360 (degrees). In the driving of an arm unit of a robot arm apparatus, a joint unit rotating past 360 (degrees) (that is, more than one full rotation) is considered unlikely, and thus making such an assumption does not pose a problem. Consequently, the detection value of the output shaft encoder 340 is not detecting the angle θ in a state of the output shaft making more than one full rotation (that is, an angle that has been reset to 0 (degrees) after exceeding 360 (degrees)), but instead may be said to be expressing the angle of the output shaft in a state in which the cumulative rotation count of the output shaft is less than one full rotation.

The output shaft angle information acquisition unit 371 acquires information about the rotational angle of the output shaft (output shaft angle information) from the output shaft encoder 340. The output shaft angle information may be information about the detection value of the rotational angle of the output shaft detected by the output shaft encoder 340. For example, the output shaft angle information acquisition unit 371 acquires information indicating that the detection value from the output shaft encoder 340 is 19.6 (degrees) as the output shaft angle information. The output shaft angle information acquisition unit 371 provides the acquired output shaft angle information to the motor cumulative rotation count computation unit 372.

The motor cumulative rotation count computation unit 372 computes the cumulative rotation count of the brushless motor 310 based on the output shaft angle information. The cumulative rotation count of the brushless motor 310 may be computed by dividing the detection value of the rotational angle of the output shaft by the value obtained by additionally dividing the rotational angle when the brushless motor 310 makes one full rotation, or in other words 360 (degrees), by the reduction ratio. In the case of the specific, exemplary numerical values discussed above, the cumulative rotation count of the brushless motor 310 may be computed like in Math. 2 below. [Math. 2] 19.6 (deg)/(360 (deg)×( 1/100))≈5.44 (rotations)   (2)

As indicated in Math. 2 above, with the exemplary numerical values discussed above, the rotation count of the brushless motor 310 is computed to be 5.44 (rotations). In the present embodiment, the motor cumulative rotation count computation unit 372 discards the value past the decimal, and computes the cumulative rotation count of the brushless motor 310 as an integer value. In the above example, the motor cumulative rotation count computation unit 372 is able to compute the cumulative rotation count of the brushless motor 310 to be 5 (rotations), based on the detection value of the rotation count on the output shaft. The motor cumulative rotation count computation unit 372 provides information about the computed cumulative rotation count of the brushless motor to the input shaft cumulative operation angle computation unit 374.

The input shaft angle information acquisition unit 373 acquires information about the rotational angle of the input shaft (input shaft angle information) from the input shaft encoder 330. The input shaft angle information may be information about the detection value of the rotational angle of the input shaft detected by the input shaft encoder 330. For example, the input shaft angle information acquisition unit 373 acquires information indicating that the detection value from the input shaft encoder 330 is 181 (degrees) as the input shaft angle information. The input shaft angle information acquisition unit 373 provides the acquired input shaft angle information to the input shaft cumulative operation angle computation unit 374.

The input shaft cumulative operation angle computation unit 374 computes a cumulative operation angle of the input shaft based on the input shaft angle information and the information about the cumulative rotation count of the brushless motor 310. Herein, the cumulative operation angle of the input shaft is the cumulative rotational angle of the input shaft since the brushless motor 310 started rotating. The cumulative operation angle of the input shaft may be computed by converting the cumulative rotation count of the brushless motor 310 to a rotational angle (in other words, multiplying by 360 (degrees)), and then adding the detection value of the rotational angle of the input shaft. In the case of the specific, exemplary numerical values discussed above, the cumulative operation angle of the input shaft may be computed like in Math. 3 below. [Math. 3] 5(rotations)×360 (deg)+181 (deg)=1981 (deg)   (3)

The input shaft cumulative operation angle computation unit 374 provides information about the computed cumulative rotation count of the input shaft to the output shaft angle computation unit 375.

The output shaft angle computation unit 375 computes the rotational angle of the output shaft based on the information about the cumulative rotation count of the input shaft. The calculated value of the rotational angle of the output shaft may be computed by dividing the cumulative rotation count of the input shaft by the reduction ratio. In the case of the specific, exemplary numerical values discussed above, the rotational angle of the output shaft may be computed like in Math. 4 below. [Math. 4] 1981(deg)×( 1/100)=19.81 (deg)   (4)

The output shaft angle computation unit 375 transmits information about the computed rotational angle of the output shaft to a control device (for example, the control device 20 in FIG. 11 discussed later) that controls the driving of joint units provided in the actuator 300 as the final detection value of the rotational angle of the output shaft. In this control device, the state of each joint unit is recognized based on the received calculated value of the rotational angle of the output shaft, and a control quantity for driving each joint unit is computed.

The above thus describes a schematic configuration of a rotational angle detection system 3 according to the present embodiment with reference to FIG. 4. As described above, in the present embodiment, the detection value of the output shaft encoder 340 is used to compute the cumulative rotation count of the motor 310, and by converting the computed cumulative rotation count of the motor 310 to a cumulative operation angle of the input shaft and adding the detection value of the input shaft encoder 330, the rotational angle of the output shaft is computed.

Herein, as discussed above, the detection value of the encoder 330 provided on the input shaft may be thought of as the rotational angle of the output shaft detected at a high resolution to the extent of the interposing reduction ratio. Consequently, the rotational angle of the output shaft converted from the detection value from the input shaft encoder 330 (181 (degrees)) via the reduction ratio may be said to be expressing the rotational angle of the output shaft more accurately than the detection value from the output shaft encoder 340 (19.6 (degrees)).

However, with the detection value from the input shaft encoder 330 (181 (degrees), it is uncertain how many full rotations the input shaft has undergone to yield “181 (degrees)”. On the other hand, when supposing a case in which the actuator 300 is applied to a joint unit provided in an arm unit of a robot arm apparatus as discussed earlier, it is justifiable to judge that the detection value from the output shaft encoder 340 (19.6 (degrees)) is an angle between 0 (degrees) and 360 (degrees). Consequently, in the present embodiment, by computing the cumulative rotation count of the motor 310 from the detection value from the output shaft encoder 340, the number of full rotations the input shaft (motor 310) has undergone to yield “181 (degrees)” is determined for the detection value from the input shaft encoder 330 (181 (degrees)). Consequently, since the cumulative operation angle of the input shaft may be computed, it becomes possible to detect the rotational angle of the output shaft based on the rotational angle of the input shaft, which is considered to be expressing the rotational angle of the output shaft more accurately.

Herein, as discussed earlier, absolute angle encoders including a magnet 331 and Hall effect sensors 332 and 333 as illustrated in FIG. 2, for example, have a simple configuration and are superior from a cost point of view, but conversely are known to have an angle detection accuracy that is not very high. However, in the present embodiment, by conducting a process of computing the rotational angle of the output shaft as discussed above, it becomes possible to compute the rotational angle of the output shaft accurately, even in the case of using such absolute angle encoders having comparatively low detection accuracy. Consequently, it becomes possible to configure the actuator 300 more compactly and at lower cost while still maintaining high accuracy in the detection of the rotational angle of the output shaft.

In addition, in the above process, the detection value from the output shaft encoder 340 is used only to compute the cumulative rotation count of the motor 310, and the portion corresponding to the remainder expressing an angle between 0 (degrees) and 360 (degrees) after computing the cumulative rotation count (for example, the “0.44” portion in the above Math. 2) is not used to compute the rotational angle of the output shaft. Consequently, in the present embodiment, error is allowable in the output shaft encoder 340 insofar as the rotation count of the motor brushless motor 310 is still computable. For example, if the reduction ratio of the reduction gear 320 is 1:100, the rotational angle of the output shaft corresponding to one full rotation of the motor 310 is 3.6 (degrees), and thus it is sufficient for the output shaft encoder 340 to have a range of 3.6 (degrees), or in other words, ±1.8 (degrees). Consequently, it is not necessary to use an encoder with particularly high accuracy as the output shaft encoder 340, making it possible to apply a comparatively cheap encoder as illustrated by example in FIG. 2, for example.

Note that in the present embodiment, a counter that holds the cumulative rotation count of the input shaft may also be provided in conjunction with the input shaft encoder 330. By providing such a counter, it is not necessary to conduct a process of computing the cumulative rotation count of the motor 310 (that is, the cumulative rotation count of the input shaft) from the detection value from the output shaft encoder 340 as discussed above, and the value of the counter may be referenced to compute the rotational angle of the output shaft. For this reason, the signal processing load on the control unit 370 may be reduced. However, if the power source is cut off and restarted, for example, the value of the counter will be reset, and thus immediately after power-on, it will be necessary to conduct a process of computing the cumulative rotation count of the motor 310 from the detection value from the output shaft encoder 340 discussed above.

3. Processing Procedure of Rotational Angle Detection Method

Next, a processing procedure of a rotational angle detection method according to the present embodiment will be described with reference to FIGS. 5 and 6. FIG. 5 is an explanatory diagram for describing a process of computing a cumulative operation angle of an input shaft while accounting for error of the input shaft, which is conducted in a rotational angle detection method according to the present embodiment. FIG. 6 is a flowchart illustrating an example of a processing procedure of a rotational angle detection method according to the present embodiment.

First, before describing the processing procedure of the rotational angle detection method according to the present embodiment in detail, a process of computing the cumulative operation angle of the input shaft while accounting for error of the input shaft will be described with reference to FIG. 5. As described with reference to FIG. 4 above, in the process of computing the rotational angle of the output shaft, the input shaft cumulative operation angle computation unit 374 performs a process of converting the cumulative rotation count of the input shaft into a cumulative operation angle, and adds the detection value of the input shaft encoder 330, as indicated in Math. 3 above. Herein, in the above description, the input shaft cumulative operation angle computation unit 374 computes the cumulative operation angle of the input shaft by directly using the cumulative rotation count of the input shaft, namely 5 (rotations). However, if the error in the detection value of the input shaft encoder 330 is large, there is a possibility that such a process by the input shaft cumulative operation angle computation unit 374 is not necessarily appropriate.

A process of computing the cumulative operation angle will be described in detail with reference to FIG. 5. In FIG. 5, the rotational angle of the input shaft and the rotational angle of the output shaft are indicated schematically as number lines. Also, at this point, a description treating the reduction ratio of the reduction gear 320 as being 1:100 will be given as an example.

The input shaft encoder 330 detects a numerical value from 0 (degrees) to 360 (degrees) while the input shaft undergoes one full rotation. Meanwhile, from the relationship with the reduction ratio, the output shaft encoder 340 detects a numerical value from 0 (degrees) to 3.6 (degrees) while the input shaft undergoes one full rotation. Consequently, the detection value of the input shaft encoder 330 corresponds to a rotational angle less than one full rotation obtained by subtracting the rotational angle corresponding to the cumulative rotation count from the detection value of the output shaft encoder 340 (that is, from 0 (degrees) to 3.6 (degrees)).

At this point, as an example, suppose that the value obtained by subtracting the rotational angle corresponding to the cumulative rotation count from the detection value of the output shaft encoder 340 is 0.9 (degrees). In this case, ideally, the detection value of the input shaft encoder 330 should be 90 (degrees), but actually, a discrepancy corresponding to detection error may be produced between the input shaft encoder 330 and the output shaft encoder 340.

For example, suppose that the detection value of the input shaft encoder 330 is 300 (degrees). In this case, this detection value of 300 (degrees) possibly may be the value of 90 (degrees) shifted by +210 (degrees), or possibly may be the value shifted by −150 (degrees). Considered more strictly, the detection value of 300 (degrees) from the input shaft encoder 330 possibly may be the value of 90 (degrees) shifted by +210 (degrees)+m×360 (degrees), or possibly may be the value shifted by −150 (degrees)+m×(−360) (degrees) (where m is an arbitrary positive integer).

In addition, in this case, it is necessary to vary the method of computing the cumulative operation angle of the input shaft according to whether the detection value of the input shaft encoder 330 is to be shifted in the positive direction or the minus direction with respect to the rotational angle of the input shaft converted from the detection value of the output shaft encoder 340. Specifically, if the detection value of 300 (degrees) from the input shaft encoder 330 is the value of 90 (degrees) shifted by +210 (degrees), the cumulative operation angle of the input shaft may be computed by directly using the cumulative rotation count of the input shaft. On the other hand, if the detection value of 300 (degrees) from the input shaft encoder 330 is the value of 90 (degrees) shifted by −150 (degrees), this 300 (degrees) expresses a rotational angle of the input shaft before making one full rotation, and thus it is necessary to compute the cumulative operation angle of the input shaft after first subtracting one full rotation from the cumulative rotation count of the input shaft. In other words, a process of correcting the cumulative rotation count of the input shaft based on the rotational angle of the input shaft converted from the detection value of the output shaft encoder 340 is conducted.

In this way, when computing the cumulative operation angle, if the detection value of the input shaft encoder 330 includes error with respect to the rotational angle of the input shaft converted from the detection value of the output shaft encoder 340, there is a problem of over what range to trust the detection value of the input shaft encoder 330. Accordingly, in the present embodiment, when computing the cumulative operation angle, a process of deciding the range over which to trust the detection value of the input shaft encoder 330 with respect to the rotational angle of the input shaft converted from the detection value of the output shaft encoder 340, and selecting a detection value of the input shaft encoder 330 included in this range as a trustworthy detection value may be conducted.

In the present embodiment, from the performance of the input shaft encoder 330, it is considered extremely unlikely that the detection value of the input shaft encoder 330 and the rotational angle of the input shaft converted from the detection value of the output shaft encoder 340 will be different by one full rotation of the input shaft or more (that is, 360 (degrees) or more). Consequently, for example, a width of 360 (degrees) (±180 (degrees)) is set as the range over which to trust the detection value of the input shaft encoder 330.

In the example illustrated in FIG. 5, a detection value of the input shaft encoder 330 included in a range of ±180 (degrees) from the rotational angle of the input shaft converted from the detection value of the output shaft encoder 340, namely 90 (degrees), is trusted. This range, as illustrated in the drawing, is the range equal to or greater than 270 (degrees) before one full rotation, and less than 270 (degrees). A detection value of the input shaft encoder 330 included in this range is adopted as a trustworthy detection value. In the above example in which the detection value of the input shaft encoder 330 is 300 (degrees), 300 (degrees) before one full rotation (300 (degrees) which is the value shifted by −150 (degrees)) included in this range is adopted as a trustworthy detection value.

At this point, on the number line indicating the range over which to trust the detection value of the input shaft encoder 330, if 0 (degrees) is included between the rotational angle of the input shaft converted from the detection value of the output shaft encoder 340, and the detection value of the input shaft encoder 330, it becomes necessary to adjust the cumulative rotation count of the input shaft when computing the cumulative operation angle. For example, if the detection value of the input shaft encoder 330 is positioned to the left of 0 (degrees) on the number line, like in the case of 300 (degrees) discussed above, it is necessary to compute the cumulative operation angle of the input shaft after first subtracting one full rotation from the cumulative rotation count of the input shaft. On the other hand, if the detection value of the input shaft encoder 330 is positioned to the right of 0 (degrees) on the number line, it is necessary to compute the cumulative operation angle of the input shaft after first adding one full rotation to the cumulative rotation count of the input shaft.

The above thus describes the process of computing the cumulative operation angle of the input shaft while accounting for error of the input shaft with reference to FIG. 5. The processing procedure of the rotational angle detection method according to the present embodiment described hereinafter with reference to FIG. 6 is a processing procedure that includes such a process of computing the cumulative operation angle of the input shaft while accounting for error of the input shaft.

Referring to FIG. 6, in the rotational angle detection method according to the present embodiment, first, angle information about the input shaft and the output shaft is acquired (step S101). This process corresponds to the process by which information about the detection values of the encoders 330 and 340 is acquired by the input shaft angle information acquisition unit 373 and the output shaft angle information acquisition unit 371 illustrated in FIG. 4, for example.

Next, based on the output shaft angle information, the cumulative rotation count of the motor 310 is computed (step S103). This process corresponds to the process by which the cumulative rotation count of the motor 310 is computed based on the output shaft angle information by the motor cumulative rotation count computation unit 372 illustrated in FIG. 4, for example. Specifically, this process may be a process of finding the maximum value of an integer n satisfying the relationship of Math. 5 below. Herein, x is the reduction ratio of the reduction gear 320, n is the cumulative rotation count of the motor, and θ_(out) is the detection value of the rotational angle of the output shaft.

$\begin{matrix} \left\lbrack {{Math}.\mspace{14mu} 5} \right\rbrack & \; \\ {n \leq \left( \frac{\theta_{out}}{360/x} \right)} & (5) \end{matrix}$

Next, based on the cumulative rotation count of the motor 310 and the output shaft angle information, the rotational angle of the input shaft estimated from the output shaft angle information (that is, the detection value of the output shaft encoder 340) is computed (step S105). This process corresponds to the process of computing the rotational angle of the input shaft converted from the detection value of the output shaft encoder 340 by subtracting the rotational angle corresponding to the cumulative rotation count from the detection value of the output shaft encoder 340, which was described with reference to FIG. 5. Specifically, this process is expressed by Math. 6 below. Herein, θ_(out-in) is the rotational angle of the input shaft estimated from the output shaft angle.

$\begin{matrix} \left\lbrack {{Math}.\mspace{14mu} 6} \right\rbrack & \; \\ {\theta_{{out} - {i\; n}} = {\left( {\theta_{out} - {\left( \frac{360}{x} \right) \times n}} \right) \times x}} & (6) \end{matrix}$

The process indicated from step S107 to step S111 conducted next corresponds to the process of deciding the range of ±180 (degrees) as the range over which to trust the detection value of the input shaft encoder 330 with respect to the rotational angle of the input shaft converted from the detection value of the output shaft encoder 340, and selecting a detection value of the input shaft encoder 330 included in this range as a trustworthy detection value, which was described with reference to FIG. 5. Specifically, first, in step S107, it is determined whether or not the computed θ_(out-in) satisfies Math. 7 below. [Math. 7] 0≤θ_(out-in)<180   (7)

In step S107, if θ_(out-in) satisfies Math. 7 above, in step S109, it is additionally determined whether or not the relationship between θ_(in), which is the detection value of the rotational angle of the input shaft, and θ_(out-in), which is the rotational angle of the input shaft converted from the detection value of the rotational angle of the output shaft, satisfies Math. 8 below. [Math. 8] θ_(in)>θ_(out-in)+180   (8)

Meanwhile, in step S107, if θ_(out-in) does not satisfy Math. 7 above, in step S111, it is additionally determined whether or not the relationship between θ_(in), which is the detection value of the rotational angle of the input shaft, and θ_(out-in), which is the rotational angle of the input shaft converted from the detection value of the rotational angle of the output shaft, satisfies Math. 9 below. [Math. 9] θ_(in)≥θ_(out-in)−180   (9)

If Math. 7 above is satisfied and Math. 8 above is also satisfied, the detection value θ_(in) of the rotational angle of the input shaft included in the trustworthy range may be determined to be positioned farther on the negative side than θ_(out-in), and also positioned to the left of 0 (degrees). Consequently, in this case, the flow proceeds to step S113, one full rotation is subtracted from n (that is, n is replaced by n−1), the computation indicated in Math. 10 below is performed, and θ_(out-c), which is the calculated value of the rotational angle of the output shaft, is computed.

$\begin{matrix} \left\lbrack {{Math}.\mspace{14mu} 10} \right\rbrack & \; \\ {\theta_{{out} - c} = {{\left( \frac{360}{x} \right) \times n} + \frac{\theta_{i\; n}}{x}}} & (10) \end{matrix}$

Meanwhile, if Math. 7 above is satisfied but Math. 8 above is not satisfied, the detection value θ_(in) of the rotational angle of the input shaft included in the trustworthy range may be determined to be positioned farther on the positive side than θ_(out-in), and also positioned to the left of 0 (degrees) (not exceeding 360 (degrees)). Consequently, in this case, the flow proceeds to step S115, n is left unchanged, the computation indicated in Math. 10 above is performed, and θ_(out-0), which is the calculated value of the rotational angle of the output shaft, is computed.

Meanwhile, if Math. 7 above is not satisfied but Math. 9 above is satisfied, similarly, the detection value θ_(in) of the rotational angle of the input shaft included in the trustworthy range may be determined to be positioned farther on the positive side than θ_(out-in), and also positioned to the left of 0 (degrees) (not exceeding 360 (degrees)). Consequently, similarly in this case, the flow proceeds to step S115, n is left unchanged, the computation indicated in Math. 10 above is performed, and θ_(out-c), which is the calculated value of the rotational angle of the output shaft, is computed.

Meanwhile, if Math. 7 above is not satisfied and Math. 9 above is also not satisfied, the detection value θ_(in) of the rotational angle of the input shaft included in the trustworthy range may be determined to be positioned farther on the positive side than θ_(out-in), and also positioned to the right of 0 (degrees) (exceeding 360 (degrees)). Consequently, in this case, the flow proceeds to step S117, one full rotation is added to n (that is, n is replaced by n+1), the computation indicated in Math. 10 above is performed, and θ_(out-c), which is the calculated value of the rotational angle of the output shaft, is computed.

Note that in terms of the configuration illustrated in FIG. 4 above, for example, the computation indicated in Math. 10 above corresponds to the processes conducted by the input shaft cumulative operation angle computation unit 374 and the output shaft angle computation unit 375.

Information about the rotational angle θ_(out-c) of the output shaft computed in the process indicated in step S113, step S115, or step S117 is transmitted to a control device (for example, the control device 20 in FIG. 11 discussed later) that controls the driving of joint units provided in the actuator 300 as the final detection value of the rotational angle of the output shaft. Subsequently, in the control device, the state of each joint unit is recognized based on θ_(out-c), and a control quantity for driving each joint unit is computed.

The above thus describes a processing procedure of a rotational angle detection method according to the present embodiment with reference to FIGS. 5 and 6. As described above, in the present embodiment, by using the detection value θ_(out) of the rotational angle of the output shaft to compute the cumulative rotation count n of the motor 310, converting the computed cumulative rotation count n of the motor 310 to a cumulative operation angle of the input shaft, and adding the detection value θ_(in) of the rotational angle of the input shaft, the calculated value θ_(out-c) of the rotational angle of the output shaft is computed. In this way, by using the higher-resolution detection value θ_(out) of the rotational angle of the output shaft to computed the cumulative operation angle of the input shaft, and using this cumulative operation angle of the input shaft to compute the rotational angle θ_(out-c) of the output shaft, the rotational angle of the output shaft may be computed more accurately.

In addition, in the present embodiment, by conducting a process of deciding a range over which to trust the detection value θ_(in) of the rotational angle of the input shaft with respect to the rotational angle θ_(out-c) of the input shaft converted from the detection value θ_(out) of the rotational angle of the output shaft, and selecting a detection value θ_(in) of the rotational angle of the input shaft included in this range as a trustworthy detection value, a process of computing the cumulative operation angle of the input shaft while accounting for detection error of the input shaft is conducted. Consequently, it becomes possible to compute the rotational angle of the output shaft with even higher accuracy.

4. Failure Detection

As illustrated in FIG. 1, the actuator 300 according to the present embodiment is equipped with encoders 330 and 340 on both the input shaft and the output shaft. In the present embodiment, such a configuration may be utilized to detect a failure of the actuator 300.

Herein, even with a typical actuator, it is possible to detect a failure of the actuator according to the detection value of the rotational angle of the output shaft, such as when the rotational angle of the output shaft is not detected even though the motor is being made to drive, for example. On the other hand, in the present embodiment, it is possible not only to detect a failure of the actuator 300, but also to detect which structural member of the actuator 300 has failed.

Specifically, given the configuration of the actuator 300 according to the present embodiment, the detection value of the input shaft encoder 330 and the detection value of the output shaft encoder 340 exist in a proportional relationship through the reduction ratio of the reduction gear 320. Consequently, if this proportional relationship is no longer observed, it may be determined that some structural member of the actuator 300 has failed. In addition, by observing changes in the detection values of the input shaft encoder 330 and the output shaft encoder 340, it is possible to determine which structural member has failed. In this way, in the present embodiment, by monitoring the detection values of the input shaft encoder 330 and the output shaft encoder 340, it becomes possible to detect a failure of the actuator 300 and the failed structural member.

Failure detection in the actuator 300 according to the present embodiment will be described in detail with reference to Table 1 below. In Table 1 below, as an example of failures that may be detected in the present embodiment, the relationship between the detection values of the input shaft encoder 330 and the output shaft encoder 340, and anticipated failure sites are summarized.

TABLE 1 Proportional Relationship Input Shaft Output Shaft of Detection Encoder Encoder Values Anticipated Failure No variation Variation in Non- Failure of input shaft encoder in detection detection proportional value value relationship Variation in No variation Non- Failure of reduction gear detection in detection proportional (idling of input shaft or lock value value relationship of output shaft) or Failure of output shaft encoder No variation No variation Non- Failure of motor in detection in detection proportional or value value relationship Failure of reduction gear (lock) Variation in Variation in Non- Failure of reduction gear detection detection proportional (idling) value value relationship

As indicated in Table 1 above, for example, if the detection value of the input shaft encoder 330 is not varying, but the detection value of the output shaft encoder 340 is varying, a conceivable state is that the detection value of the input shaft encoder 330 is not changing even though the motor 310 is driving. Consequently, in this case, it is anticipated that the input shaft encoder 330 has failed.

As another example, if the detection value of the input shaft encoder 330 is varying, but the detection value of the output shaft encoder 340 is not varying, a conceivable state is that the detection value of the output shaft encoder 340 is not changing even though the motor 310 is driving. Consequently, in this case, it is anticipated that the reduction gear 320 has failed and the rotation of the motor 310 is not being transmitted correctly to the output shaft (in other words, the input shaft is idling or the output shaft is locked in the reduction gear 320), or alternatively, the output shaft encoder 340 has failed.

As another example, if the detection value of the input shaft encoder 330 and the detection value of the output shaft encoder 340 both are not varying, it is anticipated that the motor 310 has failed and is not driving. Alternatively, it is anticipated that the input shaft and the output shaft of the reduction gear 320 are locked, and the driving of the motor 310 is being inhibited even though the motor 310 is attempting to drive.

As another example, if the detection value of the input shaft encoder 330 and the detection value of the output shaft encoder 340 both are varying, but there is not a proportional relationship between the two, it is anticipated that although the motor 310, the detection value of the input shaft encoder 330, and the output shaft encoder 340 are driving normally, the reduction gear 320 has failed, and the rotation of the motor 310 is not being transmitted to the output shaft normally (at a certain reduction ratio).

The above thus describes the failure detection function in the actuator 300 according to the present embodiment. As described above, in the present embodiment, by monitoring the detection values of the input shaft encoder 330 and the output shaft encoder 340, a failure of the actuator 300 may be detected. Furthermore, from the way in which the detection values of the input shaft encoder 330 and the output shaft encoder 340 vary, it is possible to detect even which structural member within the actuator 300 has failed. Consequently, if a failure occurs in a system made up of multiple actuators 300, it is possible to rapidly detect which structural member of which actuator 300 has failed. Thus, it becomes possible to take measures so as to not suspend the entire system, such as by suspending only the actuator 300 where the failure was detected, and maintaining driving of the system with the other actuators 300, for example.

5. Application to Robot Arm Apparatus for Medical Use

The actuator 300 according to the present embodiment is favorably applicable as an actuator that drives a joint unit of a robot arm apparatus for medical use. Hereinafter, first, the requisites demanded of an actuator in a robot arm apparatus for medical use will be described. Next, a typical known actuator and the actuator 300 according to the present embodiment will be compared from the perspective of whether or not these requisites are satisfied.

First, the requisites demanded of an actuator in a robot arm apparatus for medical use will be described. In a robot arm apparatus for medical use, any of various types of tools, or an imaging device such as an endoscope, a microscope, or a camera, is attached to the front edge of an arm unit, for example. The surgeon, by operating the arm unit, performs various treatments on an affected part of a patient with a tool, or perform various medical procedures such as surgeries and examinations while observing the affected part with the imaging device, for example. Consequently, to perform medical procedures smoothly, and also not to injure the patient unintentionally, the driving of the arm unit must be controlled accurately.

The arm unit has a configuration in which multiple links are joined by multiple joint units, and by causing an actuator provided in each joint unit to drive, the arm unit drives as a whole. Since the angle of each joint unit in the arm unit is controlled according to the rotational angle of the output shaft in the actuator, to control the driving of the arm unit accurately, accurate detection of the rotational angle of each joint unit, or in other words the rotational angle of the output shaft of the actuator, is demanded.

In addition, in a robot arm apparatus for medical use, driving control during an emergency, such as when a power outage or a failure has occurred, for example, becomes important. For example, a configuration enabling the continuation of surgery as much as possible is demanded, even if some kind of failure occurs in the robot arm apparatus for medical use in the middle of surgery.

For example, consider the case in which the power source for the robot arm apparatus is temporarily cut off due to a power outage or the like, and then restored again. In such a case, with an encoder that detects the rotational angle of a rotary shaft according to a relative angle from a reference position, such as with a relative angle encoder, the relative position relationship with the reference position will be reset when the power is temporarily cut off, and thus the angle cannot be detected immediately upon power restoration. For this reason, it becomes necessary to perform a home seek process as an initialization operation, in which the joint unit is driven to a position corresponding to the reference position, and the relative angle encoder back is returned to the reference position. For example, if a power outage occurs while in the middle of performing surgery using the robot arm apparatus for medical use, and then the power is restored and such an initialization operation is conducted, the arm unit will move in a way unintended by the surgeon, and thus there is a risk of injuring the patient. Consequently, in the actuator used in a robot arm apparatus for medical use, a configuration capable of detecting the rotational angle of the output shaft immediately after power-on, without requiring such an initialization operation, is demanded.

As another example, consider the case in which the actuator of a joint unit in the arm unit fails while in the middle of performing surgery using the robot arm apparatus for medical use, and normal operation is no longer conducted. Even in such a case, depending on the type of the surgery, interrupting the surgeon immediately may not be possible, and it may be necessary to continue the surgery by some means. Consequently, in a robot arm apparatus for medical use, there is demand for control to be conducted so that the arm unit is driven as much as possible by suspending the driving of only of the failed joint unit and controlling the driving of the other normal joint units, for example. To conduct such control, when a failure is detected, there is demand for a configuration capable of identifying the actuator where the failure was detected, and detecting which functions of the actuator are no longer executable due to the failure.

The above thus describes the requisites demanded of an actuator in a robot arm apparatus for medical use. To summarize the content described above, the following requisites are demanded of an actuator in a robot arm apparatus for medical use. Namely, the ability to detect the rotational angle of the output shaft accurately (hereinafter abbreviated as the “rotational angle detection requisite”), the ability to do without an initialization operation at power-on (hereinafter abbreviated as the “initialization operation requisite”), and the ability to self-detect (in each actuator) the occurrence of a failure (hereinafter abbreviated as the “failure detection requisite”) are demanded. Hereinafter, configurations of typical known actuators and a configuration of the actuator 300 according to the present embodiment discussed above will be compared to describe whether or not these requisites may be satisfied.

First, configurations of typical actuators will be described as the configurations (A) to (E). Note that even among the configuration of the actuator, whether or not each of the above requisites is satisfied depends greatly on the placement and type of encoder. Accordingly, in the following description, typical actuators are classified into (A) to (E) with particular focus on the configuration of the encoder. Even in the typical actuators described as the configurations (A) to (E), a brushless motor and a reduction gear similar to the present embodiment as illustrated in FIG. 1, for example, may be used as the motor and the reduction gear.

(A. Input Shaft: Motor Driving Hall Effect Sensor/Output Shaft: Absolute Angle Encoder)

The configuration (A) is a configuration in which a motor driving Hall effect sensor is provided on the input shaft, and an absolute angle encoder is provided on the output shaft. The configuration (A) is a configuration widely used in typical actuators. The motor driving Hall effect sensor is provided to drive a brushless motor, and includes a function of detecting the rotation of the rotor of the brushless motor. However, the rotational angle of the rotor (or the input shaft) is not detected as a numerical value from 0 (degrees) to 360 (degrees) like with an encoder. On the other hand, in the configuration (A), the rotational angle of the output shaft is detected by an absolute angle encoder.

Herein, with an absolute angle encoder, it is not necessary to perform a home seek initialization operation at power-on, and the rotational angle of a rotary shaft may be detected immediately. However, since the detection value is within a range from 0 (degrees) to 360 (degrees), if the rotary shaft rotates one full rotation or more (360 (degrees) or more), for example, the correct rotational angle cannot be detected unless the encoder is combined with a configuration that holds the cumulative rotation count, such as a counter, for example. If the power source is cut off, the counter information may also be reset, and thus even with an absolute angle encoder, if the rotary shaft rotates one full rotation or more, the need to perform a home seek initialization operation at power-on may be produced.

On the other hand, in an actuator used in a robot arm apparatus for medical use being considered herein, the rotational angle of the output shaft is expected to be within 0 to 360 (degrees). However, since the rotational angle of the input shaft is configured to be transmitted to the output shaft through a certain reduction ratio, the rotational angle of the input shaft may exceed this range (in other words, rotate one full rotation or more). Consequently, to satisfy the “initialization operation requisite” as an actuator of a robot arm apparatus for medical use, the provision of an absolute angle encoder on the output shaft is demanded. In this point, with the configuration (A), the “initialization operation requisite” is satisfied.

In addition, in the configuration (A), by providing an encoder on the output shaft, a failure of the actuator itself may be detected, such as when the rotational angle of the output shaft is not detected even though the motor is driving, for example. In other words, the “failure detection requisite” is also satisfied.

However, in the configuration (A), since an encoder is not provided on the input shaft, the process of computing the rotational angle of the output shaft like in the present embodiment, as described in <2. Configuration of rotational angle detection system> above and <3. Processing procedure of rotational angle detection method> above, cannot be performed. Consequently, to satisfy the “rotational angle detection requisite”, it is necessary to use an encoder capable of detecting the rotational angle with high accuracy as the absolute angle encoder provided on the output shaft. Such a high-accuracy absolute angle encoder is comparatively bulky and also costly. Consequently, in the case of attempting to satisfy the “rotational angle detection requisite” with the configuration (A), there is a possibility that the configuration of the actuator may become bulky, and costs may also increase.

(B. Input Shaft: Motor Driving Hall Effect Sensor/Output Shaft: Pulse Encoder (Relative Angle Encoder))

The configuration (B) is a configuration in which a motor driving Hall effect sensor is provided on the input shaft, and a pulse encoder is provided on the output shaft. The provision of a motor driving Hall effect sensor on the input shaft is similar to the configuration (A) above. On the other hand, the pulse encoder provided on the output shaft is one in which a disc having slits radially formed thereon is made to rotate, and by shining a light (such as a laser) onto the disc and detecting the light passing through the slits, the rotational angle of the disc is detected as the rotational angle of a rotary shaft. The pulse encoder is a type of relative angle encoder in which a certain position on the disc is treated as a reference position, and the relative rotational angle from the reference position is detected.

In the configuration (B), similarly to the configuration (A), by providing an encoder on the output shaft, a failure of the actuator itself may be detected, such as when the rotational angle of the output shaft is not detected even though the motor is driving, for example. In other words, the “failure detection requisite” is satisfied.

On the other hand, in a pulse encoder, the rotational angle is detected as a result of a detection count of light passing through the slits as the disc rotates being held by a counter. Consequently, if the power source is cut off and the counter information is reset, it is necessary to perform a home seek initialization operation. In this way, in the configuration (B), the “initialization operation requisite” is not satisfied.

Furthermore, in the configuration (B), similarly to the configuration (A), since an encoder likewise is not provided on the input shaft, a process of computing the rotational angle of the output shaft like the present embodiment cannot be conducted. Consequently, to satisfy the “rotational angle detection requisite”, it is necessary to use an encoder capable of detecting the rotational angle with high accuracy as the absolute angle encoder provided on the output shaft. Thus, there is a possibility that the configuration of the actuator may become bulky, and costs may also increase.

(C. Input Shaft: Motor Driving Hall Effect Sensor and Pulse Encoder/Output Shaft: None)

The configuration (C) is a configuration in which a motor driving Hall effect sensor and a pulse encoder are provided on the input shaft, while an encoder is not provided on the output shaft. In this way, by providing an encoder on the input shaft, it becomes possible to detect the rotational angle of the output shaft accurately (at high resolution) to the extent of the interposed reduction ratio. Consequently, in the configuration (C), the “rotational angle detection requisite” is considered to be satisfied to some degree.

However, in the configuration (C), similarly to the configuration (B), because a pulse encoder is used, it is necessary to perform a home seek initialization operation if the power source is cut off. In this way, in the configuration (C), the “initialization operation requisite” is not satisfied.

Also, in the configuration (C), an encoder is not provided on the output shaft. Consequently, although it is possible to detect failures that may be determined from the rotational state of the input shaft, such as the motor not driving, for example, the rotational angle of the output shaft is not detected, and thus it is not possible to detect failures in or downstream from the reduction gear that may be determined from the rotational state of the output shaft. Consequently, in the configuration (C), the “failure detection requisite” is not considered to be satisfied adequately.

(D. Input Shaft: Absolute Angle Encoder/Output Shaft: None)

The configuration (D) is a configuration in which an absolute angle encoder is provided on the input shaft, while an encoder is not provided on the output shaft. In the configuration (D), the absolute angle encoder is also able to fulfill the role of a motor driving Hall effect sensor. Also, similarly to the configuration (C), because an encoder is provided on the input shaft, it becomes possible to detect the rotational angle of the output shaft accurately (at high resolution) to the extent of the interposed reduction ratio. Consequently, in the configuration (D), the “rotational angle detection requisite” is considered to be satisfied to some degree.

However, as discussed above, since the rotational angle of the input shaft is transmitted to the output shaft through a certain reduction ratio, even if the change in the output rotational angle ranges from 0 (degrees) to 360 (degrees), the rotational angle of the input shaft may exceed this range (in other words, rotate one full rotation or more). Consequently, the absolute angle encoder on the input shaft must be used in conjunction with a counter for holding the cumulative rotation count. Consequently, if the power source is cut off and the counter information is reset, it is necessary to perform a home seek initialization operation. In this way, in the configuration (D), the “initialization operation requisite” is not satisfied.

Also, in the configuration (D), similarly to the configuration (C), since an encoder is not provided on the output shaft, it is not possible to detect failures that may be determined from the rotational state of the output shaft in or downstream from the reduction gear. Consequently, in the configuration (D), the “failure detection requisite” is not considered to be satisfied adequately.

(E. Input Shaft: Absolute Angle Encoder and Geared Rotary Counter/Output Shaft: None))

The configuration (E) is a configuration in which an absolute angle encoder and a geared rotary counter is provided on the input shaft, while an encoder is not provided on the output shaft. The configuration (E) corresponds to the configuration (D) with the addition of a geared rotary counter on the input shaft. In the configuration (E), similarly to the configuration (D), the absolute angle encoder is also able to fulfill the role of a motor driving Hall effect sensor. Also, similarly to the configuration (D), because an encoder is provided on the input shaft, it becomes possible to detect the rotational angle of the output shaft accurately (at high resolution) to the extent of the interposed reduction ratio. Consequently, in the configuration (E), the “rotational angle detection requisite” is considered to be satisfied to some degree.

Herein, the added geared rotary counter in the configuration (E) is a mechanically operable counter, and is able to hold information even without an electrical input. Consequently, in the geared rotary counter, the counter information is not reset even if the power source is cut off. Thus, by using the geared rotary counter in conjunction with an absolute angle encoder, and holding the cumulative rotation count of the input shaft with the geared rotary counter, it is not necessary to perform a home seek initialization operation even when the power source is cut off. Consequently, the rotational angle may be detected immediately at power-on. In this way, in the configuration (E), the “initialization operation requisite” is satisfied.

However, in the configuration (E), similarly to the configurations (C) and (D), since an encoder is not provided on the output shaft, it is not possible to detect failures that may be determined from the rotational state of the output shaft in or downstream from the reduction gear. Consequently, in the configuration (E), the “failure detection requisite” is not considered to be satisfied adequately.

In addition, due to the mechanism of the geared counter, an upper limit exists for the counter value. Consequently, a boundary naturally also exists for the cumulative rotation count of the input shaft. This means that the reduction ratio cannot be set to a set value or greater, and thus the freedom in the design of the actuator is reduced. In addition, since the structural members increase in correspondence with the provision of the geared counter, there is also a concern that the actuator may become bulkier.

The above thus describes the configurations (A) to (E) as example configurations of a typical actuator, while in addition, for each of these configurations, the above describes whether or not the requisites demanded of an actuator in a robot arm apparatus for medical use (the “rotational angle detection requisite”, the “initialization operation requisite”, and the “failure detection requisite”) are satisfied. As described above, in the configurations (A) to (E), satisfying all of these requisites is considered to be difficult.

At this point, whether or not each of the above requisites are satisfied by the actuator 300 according to the present embodiment will be considered. The actuator 300 according to the present embodiment, has a configuration in which absolute angle encoders 330 and 340 are provided on both the input shaft and the output shaft, as illustrated in FIG. 1, for example. According to this configuration, the absolute angle encoder 330 provided on the input shaft is also able to fulfill the role of a motor driving Hall effect sensor, and thus a more compact actuator 300 may be realized. Also, because the absolute angle encoder 330 is provided on the input shaft, it becomes possible to detect the rotational angle of the output shaft accurately (at high resolution) to the extent of the interposed reduction ratio. Consequently, in the actuator 300, the “rotational angle detection requisite” is satisfied.

In addition, in the actuator 300, because an absolute angle encoder 340 is provided on the output shaft, even if the power source is cut off, it is not necessary to conduct a home seek initialization operation when power is restored. Consequently, the rotational angle may be detected immediately at power-on. In this way, in the actuator 300, the “initialization operation requisite” is satisfied.

Furthermore, in the actuator 300, because the absolute angle encoders 330 and 340 on both the input shaft and the output shaft, it is possible to detect failures that may be determined from the rotational state of the input shaft, such as the motor not driving, while in addition, it is also possible to detect failures that may be determined from the rotational state of the output shaft, such as a malfunction of the reduction gear. In addition, by monitoring the proportional relationship between the detection values of the input shaft encoder 330 and the output shaft encoder 340, and the variations in these detection values, it also becomes possible to detect the failed structural member, as described in <4. Failure detection> above. In this way, in the actuator 300, the “failure detection requisite” is satisfied.

As described above, according to the present embodiment, an actuator 300 that satisfies all requisites demanded of an actuator in a robot arm apparatus for medical use (the “rotational angle detection requisite”, the “initialization operation requisite”, and the “failure detection requisite”) is provided. As a result, more accurate and safer driving control of a robot arm apparatus is realized.

Note that although the above describes the “rotational angle detection requisite”, the “initialization operation requisite”, and the “failure detection requisite” as the requisites demanded of an actuator in a robot arm apparatus for medical use, these requisites may also exist even in other applications, or in other words, other applications for which rotational angle detection with high safety and high accuracy is demanded may also exist. For example, rotational angle detection with high safety and high accuracy naturally is demanded of equipment that runs with people onboard, such as an actuator used in an automobile, such as for power steering, or an actuator used to drive playground equipment in an amusement park, for example. The actuator 300 according to the present embodiment is favorably applicable not only to robot apparatus for medical use, but also to such automobiles and playground equipment.

6. Application Example

As discussed above, the actuator 300 according to the present embodiment is favorably applicable to a joint unit of a robot arm apparatus for medical use. Hereinafter, as one application example of the actuator 300 according to the present embodiment, the configuration of a robot arm control system and a processing procedure of a robot arm control method for controlling the driving of a robot arm apparatus to which the actuator 300 may be applied will be described.

(6-1. Investigation of Robot Arm Apparatus for Medical Use)

First, to further elucidate the present disclosure, the background leading up to the inventors' conception of the embodiment described below will be described.

Recently, in medical fields and industrial fields, robot apparatuses are being used widely to perform work more accurately and more quickly. Here, position control and force control are known as control methods of the robot apparatus and each of the joint units. In position control, for example, a command value such as an angle is provided to an actuator of a joint unit, and driving of the joint unit is controlled according to the command value. Meanwhile, in force control, a target value of force applied to a task target by a whole robot apparatus is given, and driving of a joint unit (for example, torque generated by the joint unit) is controlled such that the force indicated by the target value is implemented.

Generally, most robot apparatuses are driven by position control since it is convenient to control and a system configuration is simple. However, position control is commonly called “hard control” since cannot easily deal with external force flexibly, and position control is not suitable for a robot apparatus performing a task while performing physical interaction (for example, physical interaction with a person) with various external worlds. Meanwhile, force control has a complicated system configuration, but can implement “soft control” of a power order, and thus force control is a control method suitable, particularly, for a robot apparatus performing physical interaction with a person and a control method having excellent usability.

For example, as an example of a robot apparatus applying force control, refer to JP 2010-188471A, which is a prior application by the same applicant as the present applicant of this specification. Patent Literature 1 discloses a robot apparatus that includes a movement mechanism configured with 2 wheels and an arm unit configured with a plurality of joint units, and performs control such that the wheels and the joint units are driven in a cooperative manner as a whole (performs whole body cooperative control).

Meanwhile, in recent years, in the medical field, attempts to use a balance arm in which various medical units (front edge units) are installed at a front edge of an arm unit when various medical procedures (for example, surgery or an examination) are performed have been made. For example, a method in which various imaging devices with imaging functions such as a microscope, an endoscope, or a camera is installed on a front edge of an arm unit of a balance arm as a front edge unit, and a practitioner (a user) performs various medical procedures while observing an image of the medical procedure part captured by the imaging device has been proposed.

However, the balance arm has to be equipped with a counter balance weight (also called a counter weight or a balancer) for maintaining balance of force when the arm unit is moved and thus a device size tends to increase. A device used in a medical procedure has to be small in size since it is necessary to secure a task space for the medical procedure, but it is difficult to meet such a demand in general balance arms being proposed. Further, in the balance arm, only some driving of the arm unit, for example, only biaxial driving for moving the front edge unit on a (two-dimensional) plane is electric driving, and manual positioning by the practitioner or a medical staff therearound is necessary for movement of the arm unit and the front edge unit. Thus, in the general balance arms, it is difficult to secure stability (for example, positioning accuracy of the front edge unit, vibration suppression, and the like) at the time of photography and secure a degree of freedom of observation by which it is possible to observe in various directions, for example, in a state in which a point of view is fixed on a certain part of a patient's body.

Particularly, when observing a surgical site with an imaging device attached to an arm unit, there is demand to be able to observe the surgical site from different distances and different angles, while keeping the viewpoint locked onto the surgical site. Such observation may be realized by causing the imaging device to perform a pivot operation, but performing a pivot operation with a balance arm requires a complex mechanical configuration as described in Patent Literature 1 above, and achieving high operability is difficult.

In light of such a situation, medical robot arm apparatuses in which driving is controlled by position control have been proposed as devices to take the place of balance arms. However, in order to more efficiently perform a medical procedure and reduce a burden on a user, high operability enabling more intuitive control of a position or posture of an arm unit and an imaging unit installed as a front edge unit by a user is necessary for driving control of a robot arm apparatus. In a robot arm apparatus in which driving is controlled by position control, it is difficult to meet such a user demand.

Accordingly, there is demand to further reduce the user burden by realizing a robot arm apparatus capable of performing driving control of the arm unit with higher stability and higher operability. Also, from the perspective of medical use, a robot arm apparatus is demanded to have properties like the following.

FIG. 7 will be referenced to describe an application example for the case of a robot arm apparatus according to an embodiment of the present disclosure being used for medical use, and the collection of properties demanded in a robot arm apparatus for medical use. FIG. 7 is an explanatory diagram for describing an application example for the case of a robot arm apparatus according to an embodiment of the present disclosure being used for medical use.

FIG. 7 schematically illustrates an exemplary medical procedure using the robot arm apparatus according to the present embodiment. Specifically, FIG. 7 illustrates an example in which a doctor serving as a practitioner (user) 520 performs surgery on a medical procedure target (patient) 540 on a medical procedure table 530, for example, using surgical instruments 521 such as a scalpel, tweezers, and forceps. In the following description, the medical procedure refers to a general concept including various kinds of medical treatments that the doctor serving as the user 520 performs on the patient of the medical procedure target 540 such as surgery or an examination. The example of FIG. 7 illustrates surgery as an example of the medical procedure, but the medical procedure using a robot arm apparatus 510 is not limited to surgery and may be various kinds of other medical procedures such as an examination using an endoscope.

The robot arm apparatus 510 according to the present embodiment is installed at the side of the medical procedure table 530. The robot arm apparatus 510 includes a base unit 511 serving as a base and an arm unit 512 extending from the base unit 511. The arm unit 512 includes a plurality of joint units 513 a, 513 b, 513 c, a plurality of links 514 a and 514 b connected by the joint units 513 a and 513 b, and an imaging unit 515 installed at the front edge of the arm unit 512. In the example illustrated in FIG. 7, for the sake of simplification, the arm unit 512 includes the 3 joint units 513 a to 513 c and the 2 links 514 a and 514 b, but practically, for example, the number and the shape of the joint units 513 a to 513 c and the links 514 a and 514 b and a direction of the driving shaft of the joint units 513 a to 513 c may be appropriately set to express a desired degree of freedom in view of a degree of freedom of the position and posture of the arm unit 512 and the imaging unit 515.

The joint units 513 a to 513 c have a function of connecting the links 514 a and 514 b to be rotatable, and as the joint units 513 a to 513 c are rotationally driven, driving of the arm unit 512 is controlled. Here, in the following description, the position of each component of the robot arm apparatus 510 is the position (coordinates) in a space specified for driving control, and the posture of each component is a direction (angle) to an arbitrary axis in a space specified for driving control. Further, in the following description, driving (or driving control) of the arm unit 512 refers to changing (controlling a change of) the position and posture of each component of the arm unit 512 by performing driving (or driving control) of the joint units 513 a to 513 c and driving (or driving control) of the joint units 513 a to 513 c.

Various kinds of medical apparatuses are connected to the front edge of the arm unit 512 as the front edge unit. In the example illustrated in FIG. 7, the imaging unit 515 is installed at the front edge of the arm unit 512 as an exemplary front edge unit. The imaging unit 515 is a unit that acquires an image (a photographed image) of a photographing target and is, for example, a camera capable of capturing a moving image or a still image. As illustrated in FIG. 7, the posture or the position of the arm unit 512 and the imaging unit 515 is controlled by the robot arm apparatus 510 such that the imaging unit 515 installed at the front edge of the arm unit 512 photographs a state of a medical procedure part of the medical procedure target 540. The front edge unit installed at the front edge of the arm unit 512 is not limited to the imaging unit 515 and may be various kinds of medical apparatuses. For example, the medical apparatus includes various kinds of units used when the medical procedure is performed such as an endoscope, a microscope, a unit having an imaging function such as the imaging unit 515, various kinds of medical procedure instruments, and an examination apparatus. As described above, the robot arm apparatus 510 according to the present embodiment is a medical robot arm apparatus equipped with a medical apparatus. Further, a stereo camera having two imaging units (camera units) may be installed at the front edge of the arm unit 512, and may perform photography so that an imaging target is displayed as a three dimensional (3D) image. Note that the robot arm apparatus 510 provided with the imaging unit 515 or a camera unit such as the stereo camera for imaging the site of the medical procedure may also be called a video microscope robot arm apparatus.

Further, a display device 550 such as a monitor or a display is installed at a position facing the user 520. The captured image of the medical procedure part captured by the imaging unit 515 is displayed on a display screen of the display device 550. The user 520 performs various kinds of treatments while viewing the captured image of the medical procedure part displayed on the display screen of the display device 550.

As described above, in the present embodiment, in the medical field, a technique of performing surgery while photographing the medical procedure part through the robot arm apparatus 510 is proposed. Here, in various kinds of medical procedures including surgery, it is necessary to reduce fatigue or a burden on the user 520 and the patient 540 by performing the medical procedure efficiently. In order to satisfy such a demand, in the robot arm apparatus 510, for example, the following capabilities are considered desirable.

First, as a first point, the robot arm apparatus 510 should secure a task space for surgery. If the arm unit 512 or the imaging unit 515 hinders a field of vision of the practitioner or impedes motion of a hand performing a treatment while the user 520 is performing various kinds of treatments on the medical procedure target 540, the efficiency of surgery is lowered. Further, in FIG. 7, although not illustrated, in an actual surgical scene, for example, a plurality of other doctors and/or nurses performing various support tasks of handing an instrument to the user 520 or checking various kinds of vital signs of the patient 540 are commonly around the user 520 and the patient 540, and there are other devices for performing the support tasks, and thus a surgical environment is complicated. Thus, a small size is desirable in the robot arm apparatus 510.

Next, as a second point, the robot arm apparatus 510 should have high operability for moving the imaging unit 515. For example, the user 520 may desire to observe the same medical procedure part at various positions and angles while performing a treatment on the medical procedure part according to a surgical part or surgical content. In order to change an angle at which the medical procedure part is observed, it is necessary to change an angle of the imaging unit 515 with respect to the medical procedure part, but at this time, it is more desirable that only a photographing angle be changed in a state in which the photographing direction of the imaging unit 515 is fixed to the medical procedure part (that is, while photographing the same part). Thus, for example, the robot arm apparatus 510 should have operability of a high degree of freedom such as a turning movement (a pivot movement) in which the imaging unit 515 moves within a surface of a cone having the medical procedure part as an apex, and an axis of the cone is used as a pivot axis in the state in which the photographing direction of the imaging unit 515 is fixed to the medical procedure part. Since the photographing direction of the imaging unit 515 is fixed to a certain medical procedure part, the pivot movement is also called point lock movement.

Further, in order to change the position and the angle of the imaging unit 515, for example, a method in which the user 520 manually moves the arm unit 512 to move the imaging unit 515 to a desired position and at a desired angle is considered. Thus, it is desirable that there be operability enabling movement of the imaging unit 515, the pivot movement, or the like to be easily performed even with one hand.

Further, there may be a demand from the user 520 to move a photographing center of a captured image captured by the imaging unit 515 from a part on which a treatment is being performed to another part (for example, a part on which a next treatment will be performed) while performing a treatment with both hands during surgery. Thus, various driving methods of the arm unit 512 are necessary such as a method of controlling driving of the arm unit 512 by an operation input from an input unit such as a pedal as well as a method of controlling driving of the arm unit 512 by a manual motion when it is desired to change the position and posture of the imaging unit 515.

As described above as the capability of the second point, the robot arm apparatus 510 should have high operability enabling easy movement, for example, by the pivot movement or the manual motion and satisfying intuition or a desire of the user 520.

Lastly, as a third point, the robot arm apparatus 510 should have stability in the driving control of the arm unit 512. The stability in the driving control of the arm unit 512 may be stability in the position and posture of the front edge unit when the arm unit 512 is driven. The stability in the driving control of the arm unit 512 also includes smooth movement and suppression of vibration (vibration suppression) of the front edge unit when the arm unit 512 is driven. For example, when the front edge unit is the imaging unit 515 as in the example illustrated in FIG. 7, if the position or the posture of the imaging unit 515 is unstable, the captured image displayed on the display screen of the display device 550 is unstable, and the user may have a feeling of discomfort. Particularly, when the robot arm apparatus 510 is used for surgery, a use method in which a stereo camera including two imaging units (camera units) is installed as the front edge unit, and a 3D image generated based on photographed images obtained by the stereo camera is displayed can be assumed. As described above, when the 3D image is displayed, if the position or the posture of the stereo camera is unstable, the user is likely to experience 3D sickness. Further, an observation range photographed by the imaging unit 515 may be enlarged up to about φ15 mm depending on a surgical part or surgical content. When the imaging unit 515 enlarges and photographs a narrow range as described above, slight vibration of the imaging unit 515 is shown as a large shake or deviation of an imaged image. Thus, high positioning accuracy with a permissible range of about 1 mm is necessary for driving control of the arm unit 512 and the imaging unit 515. As described above, high-accuracy responsiveness and high positioning accuracy are necessary in driving control of the arm unit 512.

The inventors have reviewed existing general balance arms and robot arm apparatuses based on position control in terms of the above-mentioned 3 capabilities.

First, with regard to securing the task space for the surgery of the first point, in the general balance arm, a counter balance weight (also called a counter weight or a balancer) for maintaining balance of force when the arm unit is moved is installed inside the base unit or the like, and thus it is difficult to reduce the size of the balance arm apparatus, and it is difficult to say that the corresponding capability is fulfilled.

Further, with regard to the high operability of the second point, in the general balance arm, only some driving of the arm unit, for example, only biaxial driving for moving the imaging unit on a (two-dimensional) plane is electric driving, and manual positioning is necessary for movement of the arm unit and the imaging unit, and thus it is difficult to say that high operability can be implemented. Further, in the general robot arm apparatus based on the position control, since it is difficult to flexibly deal with external force by the position control used for driving control of the arm unit, that is, control of the position and posture of the imaging unit, the position control is commonly called “hard control” and is not suitable of implementing desired operability satisfying the user's intuition.

Further, with regard to stability in driving control of the arm unit of the third point, the joint unit of the arm unit generally has factors that are not easily modelized such as friction, inertia, and the like. In the general balance arm or the robot arm apparatus based on the position control, the factors serve as a disturbance in the driving control of the joint unit, and even when a theoretically appropriate control value (for example, a current value applied to a motor of the joint unit) is given, there are cases in which desired driving (for example, rotation at a desired angle in the motor of the joint unit) is not implemented, and it is difficult to implement high stability necessary for driving control of the arm unit.

As described above, the inventors have reviewed robot arm apparatuses being used for medical purposes and learned that there is a demand for the capabilities of the above-mentioned three points with regard to the robot arm apparatus. However, it is difficult for the general balance arm or the robot arm apparatus based on the position control to easily fulfill such capabilities. The inventors have developed a robot arm apparatus, a robot arm control system, a robot arm control method, and a program according to the disclosure as a result of reviewing configurations satisfying the capabilities of the three points. Hereinafter, a preferrable embodiments of the configuration developed by the inventors will be described in detail.

(6-2. Embodiment of Present Disclosure)

A robot arm control system according to an embodiment of the present disclosure will be described below. In the robot arm control system according to the present embodiment, driving of a plurality of joint units installed in the robot arm apparatus is controlled by whole body cooperative control using generalized inverse dynamics. Further, ideal joint control of implementing an ideal response to a command value by correcting influence of a disturbance is applied to driving control of the joint unit.

In the following description of the present embodiment, an external appearance of the robot arm apparatus according to the present embodiment and a schematic configuration of the robot arm apparatus will be first described in (6-2-1. External appearance of robot arm apparatus). Then, an overview of the generalized inverse dynamics and the ideal joint control used for control of the robot arm apparatus according to the present embodiment will be described in (6-2-2. Generalized inverse dynamics) and (6-2-3. Ideal joint control). Then, a configuration of a system for controlling the robot arm apparatus according to the present embodiment will be described with reference to a functional block diagram in (6-2-4. Configuration of robot arm control system). Lastly, a specific example of the whole body cooperative control using the generalized inverse dynamics in the robot arm apparatus according to the present embodiment will be described in (6-2-5. Specific example of purpose of motion).

Further, the following description will proceed with an example in which a front edge unit of an arm unit of a robot arm apparatus according to an embodiment of the present disclosure is an imaging unit, and a medical procedure part is photographed by the imaging unit during surgery as illustrated in FIG. 7 as an embodiment of the present disclosure, but the present embodiment is not limited to this example. The robot arm control system according to the present embodiment can be applied even when a robot arm apparatus including a different front edge unit is used for another purpose.

(6-2-1. External Appearance of Robot Arm Apparatus)

First, a schematic configuration of a robot arm apparatus according to an embodiment of the present disclosure will be described with reference to FIG. 8. FIG. 8 is a schematic diagram illustrating an external appearance of a robot arm apparatus according to an embodiment of the present disclosure.

Referring to FIG. 8, a robot arm apparatus 400 according to the present embodiment includes a base unit 410 and an arm unit 420. The base unit 410 serves as the base of the robot arm apparatus 400, and the arm unit 420 extends from the base unit 410. Although not illustrated in FIG. 8, a control unit that controls the robot arm apparatus 400 in an integrated manner may be installed in the base unit 410, and driving of the arm unit 420 may be controlled by the control unit. For example, the control unit is configured with various kinds of signal processing circuits such as a central processing unit (CPU) or a digital signal processor (DSP).

The arm unit 420 includes a plurality of joint units 421 a to 421 f, a plurality of links 422 a to 422 c that are connected with one another by the joint units 421 a to 421 f, and an imaging unit 423 installed at the front edge of the arm unit 420.

The links 422 a to 422 c are rod-like members, one end of the link 422 a is connected with the base unit 410 through the joint unit 421 a, the other end of the link 422 a is connected with one end of the link 422 b through the joint unit 421 b, and the other end of the link 422 b is connected with one end of the link 422 c through the joint units 421 c and 421 d. Further, the imaging unit 423 is connected to the front edge of the arm unit 420, that is, the other end of the link 422 c through the joint units 421 e and 421 f. As described above, the arm shape extending from the base unit 410 is configured such that the base unit 410 serves as a support point, and the ends of the plurality of links 422 a to 422 c are connected with one another through the joint units 421 a to 421 f.

The imaging unit 423 is a unit that acquires an image of a photographing target, and is, for example, a camera that captures a moving image, a still image. The driving of the arm unit 420 is controlled such that the position and posture of the imaging unit 423 are controlled. In the present embodiment, for example, the imaging unit 423 photographs some regions of the body of the patient serving as the medical procedure part. Here, the front edge unit installed at the front edge of the arm unit 420 is not limited to the imaging unit 423, and various kinds of medical apparatuses may be connected to the front edge of the arm unit 420 as the front edge unit. As described above, the robot arm apparatus 400 according to the present embodiment is a medical robot arm apparatus equipped with a medical apparatus.

Here, the description of the robot arm apparatus 400 will proceed with coordinate axes defined as illustrated in FIG. 8. Further, a vertical direction, a longitudinal direction, and a horizontal direction are defined according to the coordinate axes. In other words, a vertical direction with respect to the base unit 410 installed on the floor is defined as a z axis direction and a vertical direction. Further, a direction along which the arm unit 420 extends from the base unit 410 as a direction orthogonal to the z axis (that is, a direction in which the imaging unit 423 is positioned with respect to the base unit 410) is defined as a y axis direction and a longitudinal direction. Furthermore, a direction that is orthogonal to the y axis and the z axis is an x axis direction and a horizontal direction.

The joint units 421 a to 421 f connect the links 422 a to 422 c to be rotatable. Each of the joint units 421 a to 421 f includes a rotation mechanism that includes an actuator and is rotationally driven on a certain rotary axis according to driving of the actuator. By controlling rotary driving in each of the joint units 421 a to 421 f, for example, it is possible to control driving of the arm unit 420 to extend or shorten (fold) the arm unit 420. Note that the actuator 300 according to the present embodiment illustrated in FIG. 1, for example, may be applied favorably as the actuator provided in the joint units 421 a to 421 f. In the present embodiment, the actuator 300 illustrated in FIG. 1 may be applied to all of the joint units 421 a to 421 f, or the actuator 300 may be applied to only to a subset of the joint units 421 a to 421 f (such as the two axes, for example). By using the actuator 300 according to the present embodiment in at least one of the joint units 421 a to 421 f, it becomes possible to drive the arm unit 420 more accurately and more safely. Here, driving of the joint units 421 a to 421 f is controlled by the whole body cooperative control which will be described in (6-2-2. Generalized inverse dynamics) and the ideal joint control which will be described in (6-2-3. Ideal joint control). Further, as described above, since the joint units 421 a to 421 f according to the present embodiment include the rotation mechanism, in the following description, driving control of the joint units 421 a to 421 f specifically means controlling a rotational angle and/or generated torque (torque generated by the joint units 421 a to 421 f) of the joint units 421 a to 421 f.

The robot arm apparatus 400 according to the present embodiment includes the 6 joint units 421 a to 421 f, and implements 6 degrees of freedom with regard to driving of the arm unit 420. Specifically, as illustrated in FIG. 7, the joint units 421 a, 421 d, and 421 f are installed such that the long axis directions of the links 422 a to 422 c connected thereto and the photographing direction of the imaging unit 473 connected thereto are set as the rotary axis direction, and the joint units 421 b, 421 c, and 421 e are installed such that an x axis direction serving as a direction in which connection angles of the links 422 a to 422 c and the imaging unit 473 connected thereto are changed within a y-z plane (a plane specified by the y axis and the z axis) is set as the rotary axis direction. As described above, in the present embodiment, the joint units 421 a, 421 d, and 421 f have a function of performing yawing, and the joint units 421 b, 421 c, and 421 e have a function of performing pitching.

As the above-described configuration of the arm unit 420 is provided, the robot arm apparatus 400 according to the present embodiment can implement the 6 degrees of freedom on driving of the arm unit 420, and thus can freely move the imaging unit 423 within a movable range of the arm unit 420. FIG. 7 illustrates a hemisphere as an exemplary movable range of the imaging unit 423. When the central point of the hemisphere is the photographing center of the medical procedure part photographed by the imaging unit 423, the medical procedure part can be photographed at various angles by moving the imaging unit 423 on the spherical surface of the hemisphere in a state in which the photographing center of the imaging unit 423 is fixed to the central point of the hemisphere.

As described above, in the present embodiment, driving of the joint units 421 a to 421 f is controlled by the ideal joint control which will be described later in (6-2-3. Ideal joint control). Thus, the actuator of the joint units 421 a to 421 f is configured to perform driving corresponding to the ideal joint control. Specifically, the actuator of the joint units 421 a to 421 f is configured to be able to adjust the rotational angles and torque associated with the rotary driving in the joint units 421 a to 421 f. Further, the actuator of the joint units 421 a to 421 f is configured to be able to arbitrarily adjust a viscous drag coefficient on a rotary motion. For example, it is possible to implement a state in which rotation is easily performed (that is, the arm unit 420 is easily moved by a manual motion) by force applied from the outside or a state in which rotation is not easily performed (that is, the arm unit 420 is not easily moved by a manual motion) by force applied from the outside.

The joint units 421 a to 421 f may have any other component in addition to the actuator. For example, in addition to the actuator, the joint units 421 a to 421 f have various kinds of components necessary for driving of the arm unit 420 such as a control unit for controlling driving of the actuator and a support member for connecting and supporting the links 422 a to 422 c and the imaging unit 423. Further, in the above description and the following description, driving of the joint unit of the arm unit may mean driving of the actuator in the joint unit.

The actuator provided in the joint units 421 a to 421 f may have a torque sensor on its output shaft. The torque sensor can detect external torque applied from the outside as well as the generated torque generated by the actuator. Thus, as the motor driver adjusts an amount of electric current supplied to the motor of the actuator based on the external torque detected by the torque sensor, it is possible to adjust the viscous drag coefficient on the rotary motion and implement, for example, the state in which rotation is easily or not easily performed by force applied from the outside.

At this point, a configuration of a torque sensor applied to an actuator according to the present embodiment will be described in detail with reference to FIGS. 9A and 9B. FIG. 9A is a schematic diagram illustrating one example configuration of a torque sensor applied to an actuator according to the present embodiment.

Referring to FIG. 9A, the torque sensor 428 according to the present embodiment includes an outer ring section 431, an inner ring section 432, beam sections 433 a to 433 d, and distortion detecting elements 434 a to 434 d. As illustrated in FIG. 9A, the outer ring section 431 and the inner ring section 432 are concentrically arranged. In the present embodiment, the inner ring section 432 is connected to an input side, that is, the output shaft of the reduction gear of the actuator, and the outer ring section 431 is connected to an output side, that is, an output member (not illustrated) at a subsequent stage. Note that in FIG. 9A, the view of the torque sensor 428 from the direction of the output shaft of the actuator is illustrated schematically.

The 4 beam sections 433 a to 433 d are arranged between the outer ring section 431 and the inner ring section 432 that are concentrically arranged, and connect the outer ring section 431 with the inner ring section 432. As illustrated in FIG. 9A, the beam sections 433 a to 433 d are interposed between the outer ring section 431 and the inner ring section 432 so that two neighboring sections of the beam sections 433 a to 433 d form an angle of 90°.

The distortion detecting elements 434 a to 434 d are installed at the two sections facing each other, that is, disposed at an angle of 180° among the beam sections 433 a to 433 d. It is possible to detect the generated torque and the external torque of the actuator based on a deformation amount of the beam sections 433 a to 433 d detected by the distortion detecting elements 434 a to 434 d.

In the example illustrated in FIG. 9A, among the beam sections 433 a to 433 d, the distortion detecting elements 434 a and 434 b are installed at the beam section 433 a, and the distortion detecting elements 434 c and 434 d are installed at the beam section 433 c. Further, the distortion detecting elements 434 a and 434 b are installed with the beam section 433 a interposed therebetween, and the distortion detecting elements 434 c and 434 d are installed with the beam section 433 c interposed therebetween. For example, the distortion detecting elements 434 a to 434 d are distortion gauges attached to the surfaces of the beam sections 433 a and 433 c, and detect geometric deformation amounts of the beam sections 433 a and 433 c based on a change in electrical resistance. As illustrated in FIG. 9A, the distortion detecting elements 434 a to 434 d are installed at 4 positions, and the detecting elements 434 a to 434 d configure a so-called Wheatstone bridge. Thus, since it is possible to detect distortion using a so-called four-gauge technique, it is possible to reduce influence of interference of shafts other than a shaft in which distortion is detected, eccentricity of the output shaft of the actuator, a temperature drift, or the like.

As described above, the beam sections 433 a to 433 d serve as a distortion inducing body whose distortion is detected. The type of the distortion detecting elements 434 a to 434 d according to the present embodiment is not limited to a distortion gauge, and any other element may be used. For example, the distortion detecting elements 434 a to 434 d may be elements that detect the deformation amounts of the beam sections 433 a to 433 d based on a change in magnetic characteristics.

Although not illustrated in FIG. 9A, the following configuration may be applied in order to improve the detection accuracy of the generated torque and the external torque by the torque sensor 428. For example, when portions of the beam sections 433 a to 433 d which are connected with the outer ring section 431 are formed at a thinner thickness than other portions, since a support moment is released, linearity of a deformation amount to be detected is improved, and influence by a radial load is reduced. Further, when both the outer ring section 431 and the inner ring section 432 are supported by a housing through a bearing, it is possible to exclude an action of other axial force and a moment from both the input shaft and the output shaft. Further, in order to reduce another axial moment acting on the outer ring section 431, a support bearing may be arranged at the input shaft side of the actuator, that is, a portion at which the motor is arranged.

The configuration of the torque sensor 428 that may be applied to the actuator according to the present embodiment has been described above with reference to FIG. 9A. As described above, through the configuration of the torque sensor 428 illustrated in FIG. 9A, it is possible to detect the generated torque and the external torque of the actuator with a high degree of accuracy.

Here, in the present embodiment, the configuration of the torque sensor 428 is not limited to the configuration illustrated in FIG. 9A and may be any other configuration. Another exemplary configuration of the torque sensor applied to the actuator other than the torque sensor 428 will be described with reference to FIG. 9B.

FIG. 9B is a schematic diagram illustrating another exemplary configuration of the torque sensor applied to the actuator according to the present embodiment. Referring to FIG. 9B, a torque sensor 428 a according to the present modified example includes an outer ring section 441, an inner ring section 442, beam sections 443 a to 443 d, and distortion detecting elements 444 a to 444 d. FIG. 9B schematically illustrates a state of the torque sensor 428 a viewed in the output axis direction of the actuator, similarly to FIG. 9A.

In the torque sensor 428 a, functions and configurations of the outer ring section 441, the inner ring section 442, the beam sections 443 a to 443 d, and the distortion detecting elements 444 a to 444 d are similar to the functions and the configurations of the outer ring section 431, the inner ring section 432, the beam sections 433 a to 433 d, and the distortion detecting elements 434 a to 434 d of the torque sensor 428 described above with reference to FIG. 9A. The torque sensor 428 a according to the present modified example differs in a configuration of a connection portion of the beam sections 443 a to 443 d and the outer ring section 441. Thus, the torque sensor 428 a illustrated in FIG. 9B will be described focusing on a configuration of the connection portion of the beam sections 443 a to 443 d and the outer ring section 441 that is the difference with the torque sensor 428 illustrated in FIG. 9A, and a description of a duplicated configuration will be omitted.

Referring to FIG. 9B, the connection portion of the beam section 443 b and the outer ring section 441 is enlarged and illustrated together with a general view of the torque sensor 428 a. In FIG. 9B, only the connection portion of the beam section 443 b and the outer ring section 441 which is one of the four connection portions of the beam sections 443 a to 443 d and the outer ring section 441 is enlarged and illustrated, but the other 3 connection portions of the beam sections 443 a, 443 c, and 443 d and the outer ring section 441 have the same configuration.

Referring to an enlarged view in FIG. 9B, in the connection portion of the beam section 443 b and the outer ring section 441, an engagement concave portion is formed in the outer ring section 441, and the beam section 443 b is connected with the outer ring section 441 such that the front edge of the beam section 443 b is engaged with the engagement concave portion. Further, gaps G1 and G2 are formed between the beam section 443 b and the outer ring section 441. The gap G1 indicates a gap between the beam section 443 b and the outer ring section 441 in a direction in which the beam section 443 b extends toward the outer ring section 441, and the gap G2 indicates a gap between the beam section 443 b and the outer ring section 441 in a direction orthogonal to that direction.

As described above, in the torque sensor 428 a, the beam sections 443 a to 443 d and the outer ring section 441 are arranged to be separated from each other with the certain gaps G1 and G2. In other words, in the torque sensor 428 a, the outer ring section 441 is separated from the inner ring section 442. Thus, since the inner ring section 442 has a degree of freedom of a motion without being bound to the outer ring section 441, for example, even when vibration occurs at the time of driving of the actuator, a distortion by vibration can be absorbed by the air gaps G1 and G2 between the inner ring section 442 and the outer ring section 441. Thus, as the torque sensor 428 a is applied as the torque sensor of the actuator, the generated torque and the external torque are detected with a high degree of accuracy.

Note that regarding an actuator compatible with ideal joint control according to the present embodiment, besides the actuator 300 described with reference to FIG. 1 above, the configurations described in previous patents by the applicant, such as JP 2009-269102A and JP 2011-209099A, for example, may also be referenced.

The schematic configuration of the robot arm apparatus 400 according to the present embodiment has been described above with reference to FIGS. 8, 9A, and 9B. Next, the whole body cooperative control and the ideal joint control for controlling driving of the arm unit 420, that is, driving of the joint units 421 a to 421 f in the robot arm apparatus 400 according to the present embodiment, will be described.

(6-2-2. Generalized Inverse Dynamics)

Next, an overview of the generalized inverse dynamics used for the whole body cooperative control of the robot arm apparatus 400 according to the present embodiment will be described.

The generalized inverse dynamics are basic operations in whole body cooperative control of a multi-link structure of converting purposes of motion related to various dimensions in various kinds of operation spaces into torque to be generated by a plurality of joint units in view of various kinds of constraint conditions in a multi-link structure (for example, the arm unit 420 illustrated in FIG. 8 in the present embodiment) configured such that a plurality of links are connected by a plurality of joint units.

The operation space is an important concept in the force control of the robot apparatus. The operation space is a space for describing a relation between force acting on the multi-link structure and acceleration of the multi-link structure. When the driving control of the multi-link structure is performed by the force control rather than the position control, the concept of the operation space is necessary in the case in which a way of dealing with the multi-link structure and the environment is used as a constraint condition. The operation space is, for example, a space to which the multi-link structure belongs such as a joint space, a Cartesian space, or a momentum space.

The purpose of motion indicates a target value in the driving control of the multi-link structure, and, for example, a target value of a position, a speed, acceleration, force, or an impedance of the multi-link structure that is desired to be achieved through the driving control.

The constraint condition is a constraint condition related to, for example, a position, a speed, acceleration, or force of the multi-link structure that is decided by the shape or the structure of the multi-link structure, the environment around the multi-link structure, a setting performed by the user, or the like. For example, the constraint condition includes information about generated force, a priority, the presence or absence of a non-driven joint, vertical reactive force, a friction weight, a support polygon, and the like.

In the generalized dynamics, in order to achieve both stability of numeric calculation and real-time processable operation efficiency, an operation algorithm is configured with a virtual force decision process (a virtual force calculating process) serving as a first stage and an actual force conversion process (an actual force calculating process) serving as a second stage. In the virtual force calculating process serving as the first stage, virtual force serving as virtual force that is necessary for achieving each purpose of motion and acts on the operation space is decided in view of a priority of a purpose of motion and a maximum value of the virtual force. In the actual force calculating process serving as the second stage, the calculated virtual force is converted into actual force that can be implemented by a configuration of an actual multi-link structure such as joint force or external force in view of a constraint related to a non-driven joint, vertical reactive force, a friction weight, a support polygon, or the like. The virtual force calculating process and the actual force calculating process will be described below. In the following description of the virtual force calculating process, the actual force calculating process, and the ideal joint control, for easier understanding, there are cases in which an exemplary configuration of the arm unit 420 of the robot arm apparatus 400 according to the present embodiment illustrated in FIGS. 8 and 3 is described as a specific example.

(6-2-2-1. Virtual Force Calculating Process)

A vector configured with certain physical quantities in the joint units of the multi-link structure is referred to as a “generalized variable q” (also referred to as a “joint value q” or a “joint space q”). An operation space x is defined by the following Equation (11) using a time differential value of the generalized variable q and a Jacobian J: [Math 11] {dot over (x)}=J{dot over (q)}   (11)

In the present embodiment, for example, q indicates a rotational angle in the joint units 421 a to 421 f of the arm unit 420. An equation of motion related to the operation space x is described by the following Equation (12): [Math 12] {umlaut over (x)}=Λ ⁻¹ f+c   (12)

Here, f indicates force acting on the operation space x. Further, Λ⁻¹ indicates an operation space inertia inverse matrix, c indicates operation space bias acceleration, and Λ⁻¹ and c are expressed by the following Equations (13) and (14). [Math 13] Λ⁻¹ =JH ⁻¹ J ^(T)   (13) c=JH ⁻¹(τ−b)+{dot over (J)}{dot over (q)}   (14)

H indicates a joint space inertia matrix, T indicates joint force (for example, generated torque in the joint units 421 a to 421 f) corresponding to the joint value q, and b is a term indicating gravity, Coriolis force, or centrifugal force.

In the generalized inverse dynamics, the purpose of motion of the position and the speed related to the operation space x is known to be expressed as acceleration of the operation space x. At this time, in order to implement the operation space acceleration serving as the target value given as the purpose of motion from Equation (11), virtual force f_(v) that has to act on the operation space x is obtained by solving a sort of linear complementary problem (LCP) expressed by the following Equation (15).

$\begin{matrix} \left\lbrack {{Math}\mspace{14mu} 14} \right\rbrack & \; \\ {{{w + \overset{¨}{x}} = {{\Lambda^{- 1}f_{v}} + c}}{s.t.\left\{ \begin{matrix} {\left( {\left( {w_{i} < 0} \right)\bigcap\left( {f_{v_{i}} = U_{i}} \right)} \right)\bigcup} \\ {\left( {\left( {w_{i} > 0} \right)\bigcap\left( {f_{v_{i}} = L_{i}} \right)} \right)\bigcup} \\ \left( {\left( {w_{i} = 0} \right)\bigcap\left( {L_{i} < f_{v_{i}} < U_{i}} \right)} \right) \end{matrix} \right.}} & (15) \end{matrix}$

Here, L_(i) and U_(i) are set to a negative lower limit value (including −∞) of an i-th component of f_(v) and a positive upper limit value (including +∞) of the i-th component of f_(v). The LCP can be solved, for example, using an iterative technique, a pivot technique, a method using robust acceleration control, or the like.

Further, the operation space inertia inverse matrix Λ⁻¹ and the bias acceleration c are large in a calculation cost when they are calculated as in Equations (13) and (14) serving as definitional equations. Thus, a method of performing the calculation process of the operation space inertia inverse matrix Λ⁻¹ at a high speed by applying a quasidynamics calculation (FWD) of calculating generalized acceleration (joint acceleration) from generalized force (the joint force τ) of the multi-link structure has been proposed. Specifically, the operation space inertia inverse matrix Λ⁻¹ and the bias acceleration c can be obtained based on information related to force acting on the multi-link structure (for example, the arm unit 420 and the joint units 421 a to 421 f) such as the joint space q, the joint force T, or the gravity g using the forward dynamics calculation FWD. As described above, the operation space inertia inverse matrix Λ⁻¹ can be calculated with a calculation amount of O(N) on the number N of joint units by applying the forward dynamics calculation FWD related to the operation space.

Here, as a setting example of the purpose of motion, a condition for achieving the target value (indicated by adding a bar above a second order differential of x) of the operation space acceleration by the virtual force f_(vi) of an absolute value F_(i) or less can be expressed by the following Equation (16): [Math 15] L _(i) =−F _(i), U _(i) =F _(i), {umlaut over (x)} _(i)= {umlaut over (x)} _(i)   (16)

As described above, the purpose of motion related to the position and the speed of the operation space x can be represented as the target value of the operation space acceleration and is specifically expressed by the following Equation (17) (the target value of the position and the speed of the operation space x are indicated by adding a bar above x and a first order differential of x). [Math 16] {umlaut over (x)} _(i) =K _(p)( x _(i) −x _(i))+K _(v)( {dot over (x)} _(i) −{dot over (x)} _(i))   (17)

It is also possible to set the purpose of motion related to the operation space (momentum, Cartesian relative coordinates, an interlocked joint, and the like) represented by a linear sum of other operation spaces using an approach of a decomposition operation space. Further, it is necessary to give priorities to competing purposes of motion. The LCP is solved for each priority or in ascending order of priorities, and it is possible to cause virtual force obtained from a previous LCP to act as known external force of a subsequent LCP.

(2-2-2. Actual Force Calculating Process)

In the actual force calculating process serving as the second stage of the generalized inverse dynamics, a process of replacing the virtual force f_(v) obtained in (2-2-1. Virtual force decision process) with actual joint force and external force is performed. A condition of implementing generalized force τ_(v)=J_(v) ^(T)f_(v) based on virtual force through generated torque τ_(a) generated by the joint unit and external force f_(e) is expressed by the following Equation (18).

$\begin{matrix} \left\lbrack {{Math}\mspace{14mu} 17} \right\rbrack & \; \\ {{\begin{bmatrix} J_{vu}^{T} \\ J_{va}^{T} \end{bmatrix}\left( {f_{v} - {\Delta\; f_{v}}} \right)} = {{\begin{bmatrix} J_{eu}^{T} \\ J_{ea}^{T} \end{bmatrix}f_{e}} + \begin{bmatrix} 0 \\ \tau_{a} \end{bmatrix}}} & (18) \end{matrix}$

Here, a subscript a indicates a set of driven joint units (a driven joint set), and a subscript u indicates a set of non-driven joint units (a non-driven joint set). In other words, the upper portions in Equation (18) represent balance of force of a space (a non-driven joint space) by the non-driven joint unit, and the lower portions represent balance of force of a space (a driven joint space) by the driven joint unit. J_(vu) and J_(va) indicate a non-driven joint component and a driven joint component of a Jacobian related to the operation space on which the virtual force f_(v) acts, respectively. J_(eu) and J_(ea) indicate a non-driven joint component and a driven joint component of a Jacobian related to the operation space on which the external force f_(e) acts. Δf_(v) indicates a component of the virtual force f_(v) that is hardly implemented by actual force.

The upper portions in Equation (18) are undefined, and, for example, f_(e) and Δf_(v) can be obtained by solving a quadratic programming problem (QP) expressed by the following Equation (19).

$\begin{matrix} \left\lbrack {{Math}\mspace{14mu} 18} \right\rbrack & \; \\ {{{\min\;\frac{1}{2}ɛ^{T}Q_{1}ɛ} + {\frac{1}{2}\xi^{T}Q_{2}\xi}}{{{s.t.\mspace{14mu} U}\;\xi} \geq v}} & (19) \end{matrix}$

Here, ε is a difference between sides of the upper portions in Equation (18), and indicates an equation error. ξ is a connection vector of f_(e) and Δf_(v), and indicates a variable vector. Q₁ and Q₂ are positive definite symmetric matrices indicating weights at the time of minimization. Further, an inequality constraint of Equation (19) is used to express a constraint condition related to external force such as vertical reactive force, a friction cone, a maximum value of external force, and a support polygon. For example, an inequality constraint related to a rectangular support polygon is expressed by the following Equation (20). [Math 19] |F _(x)|≤μ_(t) F _(z), |F _(y)|≤μ_(t) F _(z), F _(z)≥0, |M _(x) |≤d _(y) F _(z), |M _(y) |≤d _(x) F _(z), |M _(z)|≤μ_(r) F _(z)   (20)

Here, z indicates a normal direction of a contact surface, and x and y indicate two orthogonal tangential directions that are vertical to z. (F_(x), F_(y), F_(z)) and (M_(x), M_(y), M_(z)) are external force and external force moment acting on a contact point. μ_(t) and μ_(r) indicate friction coefficients related to translation and rotation. (d_(x),d_(y)) indicates a size of a support polygon.

The solutions f_(e) and Δf_(v) of a minimum norm or a minimum error are obtained from Equations (19) and (20). It is possible to obtain the joint force τ_(a) necessary for implementing the purpose of motion by substituting f_(e) and Δf_(v) obtained from Equation (19) into the lower portion of Equation (18).

In the case of a system in which the basis is fixed, and there is no non-driven joint, all virtual force can be replaced only with joint force, and f_(e)=0 and Δf_(v)=0 can be set in Equation (18). In this case, the following Equation (21) can be obtained for the joint force τ_(a) from the lower portions in Equation (18). [Math 20] τ_(a) =J _(va) ^(T) f _(v)   (21)

The whole body cooperative control using the generalized inverse dynamics according to the present embodiment has been described above. As described above, as the virtual force calculating process and the actual force calculating process are sequentially performed, it is possible to obtain the joint force τ_(a) for achieving a desired purpose of motion. In other words, conversely, as the calculated joint force τ_(a) is reflected in a theoretical model in motion of the joint units 421 a to 421 f, the joint units 421 a to 421 f are driven to achieve a desired purpose of motion.

Further, for example, JP 2009-95959A and JP 2010-188471A which are patent applications previously filed by the present applicant can be referred to for the whole body cooperative control using the generalized inverse dynamics described above, particularly, for the details of a process of deriving the virtual force f_(v), a method of solving the LCP and obtaining the virtual force f_(v), the resolution to the QP problem, and the like.

(6-2-3. Ideal Joint Control)

Next, the ideal joint control according to the present embodiment will be described. Motion of each of the joint units 421 a to 421 f is modelized by an equation of motion of a second order delay system of the following Equation (22): [Math 21] I _(a) {umlaut over (q)}=τ _(a)+τ_(e) −v _(a) {dot over (q)}   (22)

Here, I_(a) indicates an inertia moment (inertia) in a joint unit, T_(a) indicates generated torque of the joint units 421 a to 421 f, T_(e) indicates external torque acting on each of the joint units 421 a to 421 f, and v_(a) indicates a viscous drag coefficient in each of the joint units 421 a to 421 f. Equation (22) can also be regarded as a theoretical model representing motion of the actuator in the joint units 421 a to 421 f.

As described above in (6-2-2. Generalized inverse dynamics), through the calculation using the generalized inverse dynamics, it is possible to calculate T_(a) serving as actual force that each of the joint units 421 a to 421 f has to use to implement the purpose of motion using the purpose of motion and the constraint condition. Thus, ideally, a response according to the theoretical model expressed by Equation (22) is implemented, that is, a desired purpose of motion is achieved by applying each calculated T_(a) to Equation (22).

However, practically, there are cases in which an error (a modelization error) between motion of the joint units 421 a to 421 f and the theoretical model expressed by Equation (22) occurs due to influence of various disturbances. The modelization error is classified into an error caused by a mass property such as a weight, a center of gravity, or a tensor of inertia of the multi-link structure and an error caused by friction, inertia, or the like in the joint units 421 a to 421 f. Of these, the modelization error of the former caused by the mass property can be relatively easily reduced at the time of construction of the theoretical model by applying high-accuracy computer aided design (CAD) data or an identification method.

Meanwhile, the modelization error of the latter caused by friction, inertia, or the like in the joint units 421 a to 421 f occurs due to a phenomenon that it is difficult to modelize, for example, friction or the like in the reduction gear provided on the actuators of the joint units 421 a to 421 f, and an unignorable modelization error may remain at the time of construction of the theoretical model. Further, there is likely to be an error between a value of an inertia I_(a) or a viscous drag coefficient v_(a) in Equation (22) and an actual value in the joint units 421 a to 421 f. The error that is hardly modelized may act as a disturbance in the driving control of the joint units 421 a to 421 f. Thus, due to influence of such a disturbance, practically, there are cases in which motion of the joint units 421 a to 421 f does not respond as in the theoretical model expressed by Equation (22). Thus, there are cases in which it is difficult to achieve the purpose of motion of the control target even when the actual force τ_(a) serving as the joint force calculated by the generalized inverse dynamics is applied. In the present embodiment, an active control system is added to each of the joint units 421 a to 421 f, and thus the response of the joint units 421 a to 421 f is considered to be corrected such that an ideal response according to the theoretical model expressed by Equation (22) is performed. Specifically, in the present embodiment, torque control of a friction compensation type using the torque sensors 428 and 428 a of the joint units 421 a to 421 f is performed, and in addition, it is possible to perform an ideal response according to an ideal value even on the inertia I_(a) and the viscous drag coefficient v_(a) for the requested generated torque T_(a) and the requested external torque T_(e).

In the present embodiment, controlling driving of the joint unit such that the joint units 421 a to 421 f of the robot arm apparatus 400 perform the ideal response expressed by Equation (22) is referred to as the ideal joint control as described above. Here, in the following description, an actuator whose driving is controlled by the ideal joint control is also referred to as a “virtualized actuator (VA)” since the ideal response is performed. The ideal joint control according to the present embodiment will be described below with reference to FIG. 10.

FIG. 10 is an explanatory diagram for describing the ideal joint control according to an embodiment of the present disclosure. FIG. 10 schematically illustrates a conceptual computing unit that performs various kinds of operations according to the ideal joint control using blocks.

Referring to FIG. 10, for example, an actuator 610 schematically illustrates a mechanism of the actuator that may be applied to the joint units 421 a to 421 f illustrated in FIG. 8, and a motor 611, a reduction gear 612, an encoder 613, and a torque sensor 614 are illustrated.

Here, when the actuator 610 performs the response according to the theoretical model expressed by Equation (22), it means that the rotational angular acceleration at the left side is achieved when the right side of Equation (22) is given. Further, as expressed in Equation (22), the theoretical model includes an external torque term T_(e) acting on the actuator 610. In the present embodiment, in order to perform the ideal joint control, the external torque T_(e) is measured by the torque sensor 614. Further, a disturbance observer 620 is applied to calculate a disturbance estimation value T _(d) serving as an estimation value of torque caused by a disturbance based on a rotational angle q of the actuator 610 measured by the encoder 613.

A block 631 represents a computing unit that performs an operation according to the ideal joint model of the joint units 421 a to 421 f expressed by Equation (22). The block 631 can receive the generated torque T_(a), the external torque T_(e), and the rotational angular velocity (the first order differential of the rotational angle q) and output the rotational angular acceleration target value (a second order differential of a rotational angle target value q^(ref)) shown at the left side of Equation (22).

In the present embodiment, the generated torque T_(a) calculated by the method described in (6-2-2. Generalized inverse dynamics) and the external torque T_(e) measured by the torque sensor 614 are input to the block 631. Meanwhile, the rotational angle q measured by the encoder 613 is input to a block 632 indicating a computing unit that performs differential operation, and thus the rotational angular velocity (the first order differential of the rotational angle q) is calculated. In addition to the generated torque T_(a) and the external torque T_(e), the rotational angular velocity calculated by the block 632 is input to the block 631, and thus the rotational angular acceleration target value is calculated by the block 631. The calculated rotational angular acceleration target value is input to a block 633.

The block 633 indicates a computing unit that calculates torque to be generated in the actuator 610 based on the rotational angular acceleration of the actuator 610. In the present embodiment, specifically, the block 633 can obtain a torque target value T ^(ref) by multiplying a nominal inertia J_(n) of the actuator 610 to the rotational angular acceleration target value. In the ideal response, a desired purpose of motion is achieved by causing the actuator 610 to generate the torque target value T ^(ref), but there are cases in which an actual response is influenced by a disturbance or the like as described above. Thus, in the present embodiment, the disturbance estimation value T _(d) is calculated by the disturbance observer 620, and the torque target value T ^(ref) is corrected using the disturbance estimation value T _(d).

A configuration of the disturbance observer 620 will be described. As illustrated in FIG. 10, the disturbance observer 620 calculates the disturbance estimation value T _(d) based on a torque command value T and the rotational angular velocity calculated from the rotational angle q measured by the encoder 613. Here, the torque command value T is a torque value to be finally generated by the actuator 610 after influence of the disturbance is corrected. For example, when no disturbance estimation value T _(d) is calculated, the torque command value T is used as the torque target value T ^(ref).

The disturbance observer 620 is configured with a block 634 and a block 635. The block 634 is a computing unit that calculates torque to be generated by the actuator 610 based on the rotational angular velocity of the actuator 610. In the present embodiment, specifically, the rotational angular velocity calculated by the block 632 based on the rotational angle q measured by the encoder 613 is input to the block 634. The block 634 can obtain the rotational angular acceleration by performing an operation expressed by a transfer function J_(n)s, that is, by differentiating the rotational angular velocity, and calculate an estimation value (a torque estimation value) of torque actually acting on the actuator 610 by multiplying the calculated rotational angular acceleration by the nominal inertia J_(n).

In the disturbance observer 620, a difference between the torque estimation value and the torque command value T is obtained, and thus the disturbance estimation value T _(d) serving as a value of torque by a disturbance is estimated. Specifically, the disturbance estimation value T _(d) may be a difference between the torque command value T in the previous control and the torque estimation value in the current control. Since the torque estimation value calculated by the block 634 is based on an actual measurement value, and the torque command value T calculated by the block 633 is based on the ideal theoretical model of the joint units 421 a to 421 f indicated by the block 631, it is possible to estimate influence of a disturbance that is not considered in the theoretical model by obtaining the difference of the two values.

The disturbance observer 620 is further provided with a low pass filter (LPF) indicated by the block 635 in order to prevent a divergence of a system. The block 635 performs an operation represented by a transfer function g/(s+g), outputs only a low frequency component in response to an input value, and stabilizes a system. In the present embodiment, a difference value between the torque estimation value calculated by the block 634 and the torque command value T ^(ref) is input to the block 635, and the low frequency component is calculated as the disturbance estimation value T _(d).

In the present embodiment, feedforward control of adding the disturbance estimation value T _(d) calculated by the disturbance observer 620 to the torque target value T ^(ref) is performed, and thus the torque command value T serving as a torque value to be finally generated by the actuator 610 is calculated. Then, the actuator 610 is driven based on the torque command value T. Specifically, the torque command value T is converted into a corresponding electric current value (an electric current command value), the electric current command value is applied to the motor 611, so that the actuator 610 is driven.

By employing the configuration described above with reference to FIG. 10, in the driving control of the joint units 421 a to 421 f according to the present embodiment, even when there is a disturbance component such as friction, it is possible for the response of the actuator 610 to follow the target value. Further, it is possible to perform the ideal response according to the inertia I_(a) and the viscous drag coefficient v_(a) assumed by the theoretical model in the driving control of the joint units 421 a to 421 f.

For example, JP 2009-269102A that is a patent application previously filed by the present applicant can be referred to for the details of the above-described ideal joint control.

The ideal joint control according to the present embodiment has been described above with reference to FIG. 10 together with the generalized inverse dynamics used in the present embodiment. As described above, in the present embodiment, the whole body cooperative control of calculating driving parameters (for example, the generated torque values of the joint units 421 a to 421 f) of the joint units 421 a to 421 f for achieving the purpose of motion of the arm unit 420 is performed in view of the constraint condition using the generalized inverse dynamics. Further, as described above with reference to FIG. 10, in the present embodiment, as correction in which influence of a disturbance is considered is performed on the generated torque value calculated by the whole body cooperative control using the generalized inverse dynamics, the ideal joint control of implementing the ideal response based on the theoretical model in the driving control of the joint units 421 a to 421 f is performed. Thus, in the present embodiment, it is possible to perform high-accuracy driving control for achieving the purpose of motion for driving of the arm unit 420.

(6-2-4. Configuration of Robot Arm Control System)

Next, a configuration of the robot arm control system according to the present embodiment in which the whole body cooperative control and the ideal joint control described in (6-2-2. Generalized inverse dynamics) and (6-2-3. Ideal joint control) are applied to the driving control of the robot arm apparatus will be described.

An exemplary configuration of the robot arm control system according to an embodiment of the present disclosure will be described with reference to FIG. 11. FIG. 11 is a functional block diagram illustrating an exemplary configuration of the robot arm control system according to an embodiment of the present disclosure. In the robot arm control system illustrated in FIG. 11, components related to driving control of the arm unit of the robot arm apparatus are mainly illustrated.

Referring to FIG. 11, a robot arm control system 1 according to an embodiment of the present disclosure includes a robot arm apparatus 10, a control device 20, and a display device 30. In the present embodiment, various kinds of operations in the whole body cooperative control described in (6-2-2. Generalized inverse dynamics) and the ideal joint control described in (6-2-3. Ideal joint control) through the control device 20 are performed, and driving of the arm unit of the robot arm apparatus 10 is controlled based on the operation result. Further, the arm unit of the robot arm apparatus 10 is provided with an imaging unit 140 which will be described later, and an image captured by the imaging unit 140 is displayed on a display screen of the display device 30. Next, configurations of the robot arm apparatus 10, the control device 20, and the display device 30 will be described in detail.

The robot arm apparatus 10 includes an arm unit having a multi-link structure configured with a plurality of joint units and a plurality of links, and drives the arm unit in the movable range to control the position and posture of the front edge unit installed at the front edge of the arm unit. The robot arm apparatus 10 corresponds to the robot arm apparatus 400 illustrated in FIG. 8.

Referring to FIG. 11, the robot arm apparatus 10 includes an arm control unit 110 and an arm unit 120. The arm unit 120 includes a joint unit 130 and the imaging unit 140.

The arm control unit 110 controls the robot arm apparatus 10 in an integrated manner, and controls driving of the arm unit 120. The arm control unit 110 corresponds to the control unit (not illustrated in FIG. 8) described above with reference to FIG. 8. Specifically, the arm control unit 110 includes a drive control unit 111, and controls driving of the arm unit 120, and driving of the arm unit 120 is controlled by controlling driving of the joint unit 130 according to control of the drive control unit 111. More specifically, the drive control unit 111 controls the number of revolutions of the motor in the actuator of the joint unit 130 and the rotational angle and the generated torque of the joint unit 130 by controlling an amount of electric current supplied to the motor. Here, as described above, driving control of the arm unit 120 by the drive control unit 111 is performed based on the operation result in the control device 20. Thus, an amount of electric current that is controlled by the drive control unit 111 and supplied to the motor in the actuator of the joint unit 130 is an amount of electric current decided based on the operation result in the control device 20. However, such a control unit may also be provided respectively for each joint unit to respectively control the driving of each joint unit.

The arm unit 120 has a multi-link structure configured with a plurality of joint units and a plurality of links, and driving of the arm unit 120 is controlled according to control of the arm control unit 110. The arm unit 120 corresponds to the arm unit 420 illustrated in FIG. 8. The arm unit 120 includes the joint unit 130 and the imaging unit 140. Further, since the plurality of joint units of the arm unit 120 have the same function and configuration, a configuration of one joint unit 130 representing the plurality of joint units is illustrated in FIG. 11.

The joint unit 130 connects links to be rotatable in the arm unit 120, and the rotary driving of the joint unit 130 is controlled according to control of the arm control unit 110 such that the arm unit 120 is driven. The joint unit 130 corresponds to the joint units 421 a to 421 f illustrated in FIG. 8. Further, the joint unit 130 includes an actuator, and the actuator has a configuration similar to, for example, the configuration illustrated in FIGS. 8, 9A, and 9B. The joint unit 130 includes a joint driving unit 131 and a joint state detecting unit 132.

The joint driving unit 131 is a driving mechanism in the actuator of the joint unit 130, and as the joint driving unit 131 is driven, the joint unit 130 is rotationally driven. The drive control unit 111 controls driving of the joint driving unit 131. For example, the joint driving unit 131 is a component corresponding to the motor 310 and the motor driver for driving the motor 310 illustrated in FIG. 1, and driving the joint driving unit 131 corresponds to the motor driver driving the motor 310 with an amount of electric current according to a command given from the drive control unit 111.

The joint state detecting unit 132 detects the state of the joint unit 130. Here, the state of the joint unit 130 may mean a motion state of the joint unit 130. For example, the state of the joint unit 130 includes information such as the rotational angle, the rotational angular velocity, the rotational angular acceleration, and the generated torque of the joint unit 130. In the present embodiment, the joint state detecting unit 132 includes a rotational angle detecting unit 133 that detects the rotational angle of the joint unit 130 and a torque detecting unit 134 that detects the generated torque and the external torque of the joint unit 130. For example, the rotational angle detecting unit 133 and the torque detecting unit 134 correspond to the encoders 330 and 340 of the actuator 300 illustrated in FIG. 1 and the torque sensors 428 and 428 a illustrated in FIGS. 9A and 9B. The joint state detecting unit 132 transmits the detected state of the joint unit 130 to the control device 20.

The imaging unit 140 is an example of the front edge unit installed at the front edge of the arm unit 120, and acquires an image of a photographing target. The imaging unit 140 corresponds to the imaging unit 423 illustrated in FIG. 8. Specifically, the imaging unit 140 is, for example, a camera capable of photographing a photographing target in a moving image format or a still image format. More specifically, the imaging unit 140 includes a plurality of light receiving elements arranged two dimensionally, and can perform photoelectric conversion in the light receiving elements and acquire an image signal indicating an image of a photographing target. The imaging unit 140 transmits the acquired image signal to the display device 30.

Further, similarly to the robot arm apparatus 400 of FIG. 8 in which the imaging unit 423 is installed at the front edge of the arm unit 420, in the robot arm apparatus 10, the imaging unit 140 is actually installed at the front edge of the arm unit 120. In FIG. 11, the form in which the imaging unit 140 is installed at the front edge of the last link through the plurality of joint units 130 and a plurality of links is represented by schematically illustrating the link between the joint unit 130 and the imaging unit 140.

Further, in the present embodiment, various kinds of medical apparatuses may be connected to the front edge of the arm unit 120 as the front edge unit. As the medical apparatus, for example, there are various kinds of units used when the medical procedure is performed such as various kinds of medical procedure instruments including a scalpel or forceps or one unit of various kinds of examination apparatuses including a probe of an ultrasonic examination apparatus. Further, in the present embodiment, the imaging unit 140 illustrated in FIG. 11 or a unit having an imaging function such as an endoscope or a microscope may also be included as a medical apparatus. As described above, the robot arm apparatus 10 according to the present embodiment may be a medical robot arm apparatus including a medical apparatus. Similarly, the robot arm control system 1 according to the present embodiment may be a medical robot arm control system. Note that the robot arm apparatus 10 illustrated in FIG. 11 may also be said to be a video microscope robot arm apparatus equipped with a unit having an imaging function as the front edge unit. Further, a stereo camera including two imaging units (camera units) may be installed at the front edge of the arm unit 120, and photography may be performed so that an imaging target is displayed as a 3D image.

The function and configuration of the robot arm apparatus 10 have been described above. Next, a function and configuration of the control device 20 will be described. Referring to FIG. 11, the control device 20 includes an input unit 210, a storage unit 220, and a control unit 230.

The control unit 230 controls the control device 20 in an integrated manner, and performs various kinds of operations for controlling driving of the arm unit 120 in the robot arm apparatus 10. Specifically, in order to control driving of the arm unit 120 of the robot arm apparatus 10, the control unit 230 performs various kinds of operations in the whole body cooperative control and the ideal joint control. The function and configuration of the control unit 230 will be described below in detail, but the whole body cooperative control and the ideal joint control have already been described in (6-2-2. Generalized inverse dynamics) and (6-2-3. Ideal joint control), and thus a description thereof will be omitted here.

The control unit 230 includes a whole body cooperative control unit 240, and an ideal joint control unit 250.

The whole body cooperative control unit 240 performs various kinds of operations related to the whole body cooperative control using the generalized inverse dynamics. In the present embodiment, the whole body cooperative control unit 240 acquires a state (an arm state) of the arm unit 120 based on the state of the joint unit 130 detected by the joint state detecting unit 132. Further, the whole body cooperative control unit 240 calculates a control value for the whole body cooperative control of the arm unit 120 in the operation space based on the arm state and the purpose of motion and the constraint condition of the arm unit 120 using the generalized inverse dynamics. For example, the operation space refers to a space for describing a relation between force acting on the arm unit 120 and acceleration generated in the arm unit 120.

The whole body cooperative control unit 240 includes an arm state acquiring unit 241, an operation condition setting unit 242, a virtual force calculating unit 243, and an actual force calculating unit 244.

The arm state acquiring unit 241 acquires the state (the arm state) of the arm unit 120 based on the state of the joint unit 130 detected by the joint state detecting unit 132. Here, the arm state may mean the motion state of the arm unit 120. For example, the arm state includes information such as a position, a speed, acceleration, or force of the arm unit 120. As described above, the joint state detecting unit 132 acquires information such as the rotational angle, the rotational angular velocity, the rotational angular acceleration, or the generated torque of each of the joint units 130 as the state of the joint unit 130. Further, as will be described later, the storage unit 220 stores various kinds of information that is processed by the control device 20, and in the present embodiment, the storage unit 220 may store various kinds of information (arm information) related to the arm unit 120, for example, the number of joint units 130 and the number of links configuring the arm unit 120, a connection state of the link and the joint unit 130, and the length of the link. The arm state acquiring unit 241 can acquire the corresponding information from the storage unit 220. Thus, the arm state acquiring unit 241 can acquire information such as the positions (coordinates) of the plurality of joint units 130, a plurality of links, and the imaging unit 140 on the space (that is, the shape of the arm unit 120 or the position and posture of the imaging unit 140) or force acting on each of the joint units 130, the link, and the imaging unit 140 based on the state of the joint unit 130 and the arm information. The arm state acquiring unit 241 transmits the acquired arm information to the operation condition setting unit 242.

The operation condition setting unit 242 sets an operation condition in an operation related to the whole body cooperative control using the generalized inverse dynamics. Here, the operation condition may be the purpose of motion and the constraint condition. The purpose of motion may be various kinds of information related to a motion of the arm unit 120. Specifically, the purpose of motion may be a target value of the position and posture (coordinates), a speed, acceleration, and force of the imaging unit 140 or a target value of the position (coordinates), a speed, acceleration, and force of the plurality of joint units 130 and a plurality of links of the arm unit 120. The constraint condition may be various kinds of information for constricting the motion of the arm unit 120. Specifically, the constraint condition may be coordinates of a region into which none of the components of the arm unit should move, values of a speed and acceleration at which the arm unit should not move, a value of force that should not be generated, or the like. Further, a constraint range of various kinds of physical quantities in the constraint condition may be set from ones that are difficult for the arm unit 120 to implement structurally or may be appropriately set by the user. Further, the operation condition setting unit 242 includes a physical model (for example, one in which the number of links configuring the arm unit 120, the length of the link, the connection state of the link through the joint unit 130, the movable range of the joint unit 130, and the like are modelized) for the structure of the arm unit 120, and may set the motion condition and the constraint condition by generating a control model in which a desired motion condition and a desired constraint condition are reflected in the physical model.

In the present embodiment, it is possible to appropriately set the purpose of motion and the constraint condition and cause the arm unit 120 to perform a desired movement. For example, it is possible to set the target value of the position of the imaging unit 140 as the purpose of motion and move the imaging unit 140 to the target position, and it is also possible to set a movement constraint according to the constraint condition, for example, to prevent the arm unit 120 from invading a certain region in a space and then drive the arm unit 120.

As a specific example of the purpose of motion, for example, the purpose of motion may be a pivot movement serving as a turning movement in which the imaging unit 140 moves within a plane of a cone having a medical procedure part as an apex, and an axis of the cone is used as a pivot axis in a state in which the photographing direction of the imaging unit 140 is fixed to the medical procedure part. In the pivot movement, the turning movement may be performed in a state in which a distance between the imaging unit 140 and a point corresponding to the apex of the cone is maintained constant. As the pivot movement is performed, it is possible to observe an observation part at an equal distance and at different angles, and thus it is possible to improve a convenience of the user performing surgery.

Another specific example, the purpose of motion may be content controlling the generated torque in each of the joint units 130. Specifically, the purpose of motion may be a power assist movement of controlling the state of the joint unit 130 such that gravity acting on the arm unit 120 is negated and controlling the state of the joint unit 130 such that movement of the arm unit 120 is supported in a direction of force given from the outside. More specifically, in the power assist movement, driving of each of the joint units 130 is controlled such that each of the joint units 130 generates the generated torque for negating external torque by gravity in each of the joint units 130 of the arm unit 120, and thus the position and posture of the arm unit 120 are held in a certain state. When external torque is further applied from the outside (for example, from the user) in this state, driving of each of the joint units 130 is controlled such that each of the joint units 1 generates the generated torque in the same direction as the applied external torque. As the power assist movement is performed, when the user manually moves the arm unit 120, the user can move the arm unit 120 by small force, and thus a feeling of moving the arm unit 120 in a non-gravity state can be given to the user. Further, it is possible to combine the pivot movement with the power assist movement.

Here, in the present embodiment, the purpose of motion may mean a movement (motion) of the arm unit 120 implemented in the whole body cooperative control or may mean an instantaneous purpose of motion (that is, the target value in the purpose of motion) in the corresponding movement. For example, in the case of the pivot movement, performing the pivot movement by the imaging unit 140 is the purpose of motion, but, for example, a value of the position or the speed of the imaging unit 140 in the cone plane in the pivot movement is set as an instantaneous purpose of motion (the target value in the purpose of motion) while the pivot movement is being performed. Further, for example, in the case of the power assist movement, performing the power assist movement for supporting movement of the arm unit 120 in the direction of force applied from the outside is the purpose of motion, but a value of the generated torque in the same direction as the external torque applied to each of the joint units 130 is set as an instantaneous purpose of motion (the target value in the purpose of motion) while the power assist movement is being performed. In the present embodiment, the purpose of motion is a concept including both the instantaneous purpose of motion (for example, the target value of the position, the speed, or force of each component of the arm unit 120 during a certain period of time) and movement of each component of the arm unit 120 implemented over time as a result of continuously achieving the instantaneous purpose of motion. In each step in an operation for the whole body cooperative control in the whole body cooperative control unit 240, the instantaneous purpose of motion is set each time, and the operation is repeatedly performed, so that a desired purpose of motion is finally achieved.

Further, in the present embodiment, when the purpose of motion is set, the viscous drag coefficient in the rotary motion of each of the joint units 130 may be appropriately set as well. As described above, the joint unit 130 according to the present embodiment is configured to be able to appropriately adjust the viscous drag coefficient in the rotary motion of the actuator. Thus, as the viscous drag coefficient in the rotary motion of each of the joint units 130 is also set at the time of setting of the purpose of motion, for example, it is possible to implement the state in which rotation is easily or not easily performed by force applied from the outside. For example, in the case of the power assist movement, as the viscous drag coefficient in the joint unit 130 is set to be small, the user can move the arm unit 120 by small force, and the user can have a non-gravity feeling. As described above, the viscous drag coefficient in the rotary motion of each of the joint units 130 may be appropriately set according to content of the purpose of motion.

The specific examples of the purpose of motion will be described again in detail in (6-2-5. Specific example of purpose of motion).

Here, in the present embodiment, as will be described later, the storage unit 220 may store a parameter related to the operation condition such as the purpose of motion or the constraint condition used in an operation related to the whole body cooperative control. The operation condition setting unit 242 can set the constraint condition stored in the storage unit 220 as the constraint condition used in the operation of the whole body cooperative control.

Further, in the present embodiment, the operation condition setting unit 242 can set the purpose of motion by a plurality of methods. For example, the operation condition setting unit 242 may set the purpose of motion based on the arm state transmitted from the arm state acquiring unit 241. As described above, the arm state includes information of the position of the arm unit 120 and information of force acting on the arm unit 120. Thus, for example, when the user manually moves the arm unit 120, information related to how the user moves the arm unit 120 is also acquired as the arm state through the arm state acquiring unit 241. Thus, the operation condition setting unit 242 can set, for example, the position to which the user has moved the arm unit 120, a speed at which the user has moved the arm unit 120, or force by which the user has moved the arm unit 120 as the instantaneous purpose of motion based on the acquired arm state. As the purpose of motion is set as described above, control is performed such that driving of the arm unit 120 follows and supports movement of the arm unit 120 by the user.

Further, for example, the operation condition setting unit 242 may set the purpose of motion based on an instruction input from the input unit 210 by the user. As will be described later, the input unit 210 is an input interface through which the user inputs, for example, information or a command related to driving control of the robot arm apparatus 10 to the control device 20, and in the present embodiment, the purpose of motion may be set based on an operation input from the input unit 210 by the user. Specifically, the input unit 210 includes an operation unit operated by the user such as a lever or a pedal, and, for example, the operation condition setting unit 242 may set the position or the speed of each component of the arm unit 120 as the instantaneous purpose of motion according to an operation of the lever, the pedal, or the like.

Further, for example, the operation condition setting unit 242 may set the purpose of motion stored in the storage unit 220 as the purpose of motion used in the operation of the whole body cooperative control. For example, in the case of the purpose of motion for causing the imaging unit 140 to stop at a certain point in the space, coordinates of the certain point can be set as the purpose of motion in advance. Further, for example, in the case of the purpose of motion for causing the imaging unit 140 to move along a certain trajectory in the space, coordinates of points indicating the certain trajectory can be set as the purpose of motion in advance. As described above, when the purpose of motion can be set in advance, the purpose of motion may be stored in the storage unit 220 in advance. Further, for example, in the case of the pivot movement, the purpose of motion is limited to setting a position, a speed, or the like in the plane of the cone as the target value, and in the case of the power assist movement, the purpose of motion is limited to setting force as the target value. As described above, when the purpose of motion such as the pivot movement or the power assist movement is set in advance, for example, information related to a range or a type of the target value that can be set as the instantaneous purpose of motion in the purpose of motion may be stored in the storage unit 220. The operation condition setting unit 242 can include and set various kinds of information related to the purpose of motion as the purpose of motion.

Further, the user may appropriately set the method of setting the purpose of motion through the operation condition setting unit 242, for example, according to the purpose of the robot arm apparatus 10. Further, the operation condition setting unit 242 may set the purpose of motion and the constraint condition by appropriately combining the above methods. Furthermore, a priority of the purpose of motion may be set to the constraint condition stored in the storage unit 220, and when there are a plurality of different purposes of motion, the operation condition setting unit 242 may set the purpose of motion according to the priority of the constraint condition. The operation condition setting unit 242 transmits the arm state, the set purpose of motion and the constraint condition to the virtual force calculating unit 243.

The virtual force calculating unit 243 calculates virtual force in the operation related to the whole body cooperative control using the generalized inverse dynamics. For example, a virtual force calculation process performed by the virtual force calculating unit 243 may be a series of processes described above in (6-2-2-1. Virtual force calculating process). The virtual force calculating unit 243 transmits the calculated virtual force f_(v) to the actual force calculating unit 244.

The actual force calculating unit 244 calculates actual force in the operation related to the whole body cooperative control using the generalized inverse dynamics. For example, an actual force calculation process performed by the actual force calculating unit 244 may be a series of processes described above in (2-2-2. Actual force calculating process). The actual force calculating unit 244 transmits the calculated actual force (the generated torque) T_(a) to the ideal joint control unit 250. Further, in the present embodiment, the generated torque T_(a) calculated by the actual force calculating unit 244 is also referred to as a “control value” or a “control torque value” to mean a control value of the joint unit 130 in the whole body cooperative control.

The ideal joint control unit 250 performs various kinds of operations related to the ideal joint control for implementing the ideal response based on the theoretical model. In the present embodiment, the ideal joint control unit 250 corrects influence of a disturbance on the generated torque T _(a) calculated by the actual force calculating unit 244, and calculates the torque command value T for implementing the ideal response of the arm unit 120. The operation process performed by the ideal joint control unit 250 corresponds to a series of processes described above in (6-2-3. Ideal joint control).

The ideal joint control unit 250 includes a disturbance estimating unit 251 and a command value calculating unit 252.

The disturbance estimating unit 251 calculates the disturbance estimation value T _(d) based on the torque command value T and the rotational angular velocity calculated from the rotational angle q detected by the rotational angle detecting unit 133. Here, the torque command value T refers to the command value indicating the generated torque of the arm unit 120 that is finally transmitted to the robot arm apparatus 10. As described above, the disturbance estimating unit 251 has a function corresponding to the disturbance observer 620 illustrated in FIG. 10.

The command value calculating unit 252 calculates the torque command value T serving as the command value indicating torque that is generated by the arm unit 120 and finally transmitted to the robot arm apparatus 10 using the disturbance estimation value Td calculated by the disturbance estimating unit 251. Specifically, the command value calculating unit 252 calculates the torque command value T by adding the disturbance estimation value id calculated by the disturbance estimating unit 251 to Tref calculated from the ideal model of the joint unit 130 expressed by Equation (22). For example, when the disturbance estimation value Td is not calculated, the torque command value T is used as the torque target value Tref. As described above, the function of the command value calculating unit 252 corresponds to a function other than that of the disturbance observer 620 illustrated in FIG. 10.

As described above, in the ideal joint control unit 250, a series of processes described above with reference to FIG. 10 is performed such that information is repeatedly exchanged between the disturbance estimating unit 251 and the command value calculating unit 252. The ideal joint control unit 250 transmits the calculated torque command value T to the drive control unit 111 of the robot arm apparatus 10. The drive control unit 111 performs control of supplying an amount of electric current corresponding to the transmitted torque command value T to the motor in the actuator of the joint unit 130, controls the number of revolutions of the motor, and controls the rotational angle and the generated torque of the joint unit 130.

In the robot arm control system 1 according to the present embodiment, since driving control of the arm unit 120 in the robot arm apparatus 10 is continuously performed while a task using the arm unit 120 is being performed, the above-described process is repeatedly performed in the robot arm apparatus 10 and the control device 20. In other words, the joint state detecting unit 132 of the robot arm apparatus 10 detects the state of the joint unit 130, and transmits the detected state of the joint unit 130 to the control device 20. In the control device 20, various kinds of operations related to the whole body cooperative control and the ideal joint control for controlling driving of the arm unit 120 are performed based on the state of the joint unit 130, the purpose of motion, and the constraint condition, and the torque command value T serving as the operation result is transmitted to the robot arm apparatus 10. In the robot arm apparatus 10, driving of the arm unit 120 is controlled based on the torque command value T, and the state of the joint unit 130 during or after driving is detected by the joint state detecting unit 132 again.

The description of the other components of the control device 20 will now continue.

The input unit 210 is an input interface through which the user inputs, for example, information or a command related to driving control of the robot arm apparatus 10 to the control device 20. In the present embodiment, based on an operation input from the input unit 210 by the user, driving of the arm unit 120 of the robot arm apparatus 10 may be controlled, and the position and posture of the imaging unit 140 may be controlled. Specifically, as described above, as the user inputs instruction information related to an instruction of arm driving input from the input unit 210 to the operation condition setting unit 242, the operation condition setting unit 242 may set the purpose of motion in the whole body cooperative control based on the instruction information. As described above, the whole body cooperative control is performed using the purpose of motion based on the instruction information input by the user, and thus driving of the arm unit 120 according to the user's operation input is implemented.

Specifically, the input unit 210 includes an operation unit operated by the user such as a mouse, a keyboard, a touch panel, a button, a switch, a lever, and a pedal, for example. For example, when the input unit 210 includes a pedal, the user can control driving of the arm unit 120 by operating the pedal by foot. Thus, even when the user performs a treatment on the patient's medical procedure part using both hands, it is possible to adjust the position and posture of the imaging unit 140, that is, the photographing position or the photographing angle of the medical procedure part through an operation of the pedal by foot.

The storage unit 220 stores various kinds of pieces of information that are processed by the control device 20. In the present embodiment, the storage unit 220 can store various kinds of parameters used in the operation related to the whole body cooperative control and the ideal joint control performed by the control unit 230. For example, the storage unit 220 may store the purpose of motion and the constraint condition used in the operation related to the whole body cooperative control performed by the whole body cooperative control unit 240. The purpose of motion stored in the storage unit 220 may be a purpose of motion that can be set in advance so that the imaging unit 140 can stop at a certain point in the space as described above, for example. Further, the constraint condition may be set by the user in advance according to the geometric configuration of the arm unit 120, the purpose of the robot arm apparatus 10, or the like and then stored in the storage unit 220. Furthermore, the storage unit 220 may store various kinds of information related to the arm unit 120 used when the arm state acquiring unit 241 acquires the arm state. Moreover, the storage unit 220 may store, for example, the operation result in the operation related to the whole body cooperative control and the ideal joint control performed by the control unit 230 and numerical values calculated in the operation process. As described above, the storage unit 220 may store all parameters related to various kinds of processes performed by the control unit 230, and the control unit 230 can perform various kinds of processes while transmitting or receiving information to or from the storage unit 220.

The function and configuration of the control device 20 have been described above. The control device 20 according to the present embodiment may be configured, for example, with various kinds of information processing devices (arithmetic processing devices) such as a personal computer (PC) or a server. Next, a function and configuration of the display device 30 will be described.

The display device 30 displays various kinds of information on the display screen in various formats such as text or an image, and visually notifies the user of the information. In the present embodiment, the display device 30 displays an image captured by the imaging unit 140 of the robot arm apparatus 10 through the display screen. Specifically, the display device 30 includes a function or component such as an image signal processing unit (not illustrated) that performs various kinds of image processing on the image signal acquired by the imaging unit 140 or a display control unit (not illustrated) that performs control such that an image based on the processed image signal is displayed on the display screen. Further, the display device 30 may have various kinds of functions and components that are equipped in a general display device in addition to the above function or component. The display device 30 corresponds to the display device 550 illustrated in FIG. 6.

The functions and configurations of the robot arm apparatus 10, the control device 20, and the display device 30 according to the present embodiment have been described above with reference to FIG. 11. Each of the above components may be configured using a versatile member or circuit, and may be configured by hardware specialized for the function of each component. Further, all the functions of the components may be performed by a CPU or the like. Thus, a configuration to be used may be appropriately changed according to a technology level when the present embodiment is carried out.

As described above, according to the present embodiment, the arm unit 120 having the multi-link structure in the robot arm apparatus 10 has at least 6 or more degrees of freedom, and driving of each of the plurality of joint units 130 configuring the arm unit 120 is controlled by the drive control unit 111. Further, the medical apparatus is installed at the front edge of the arm unit 120. As driving of each joint unit 130 is controlled as described above, driving control of the arm unit 120 having a high degree of freedom is implemented, and the robot arm apparatus 10 for medical use having high operability for a user is implemented.

More specifically, according to the present embodiment, in the robot arm apparatus 10, the state of the joint unit 130 is detected by the joint state detecting unit 132. Further, in the control device 20, based on the state of the joint unit 130, the purpose of motion, and the constraint condition, various kinds of operations related to the whole body cooperative control using the generalized inverse dynamics for controlling driving of the arm unit 120 are performed, and torque command value T serving as the operation result are calculated. Furthermore, in the robot arm apparatus 10, driving of the arm unit 120 is controlled based on the torque command value T. As described above, in the present embodiment, driving of the arm unit 120 is controlled by the whole body cooperative control using the generalized inverse dynamics. Thus, driving control of the arm unit 120 according to the force control is implemented, and the robot arm apparatus having the high operability for the user is implemented. Further, in the present embodiment, in the whole body cooperative control, for example, control for implementing various kinds of purposes of motion for improving user convenience such as the pivot movement and the power assist movement can be performed. Furthermore, in the present embodiment, for example, various driving units for moving the arm unit 120 manually or through an operation input from a pedal are implemented, and thus user convenience is further improved.

Further, in the present embodiment, the whole body cooperative control and the ideal joint control are applied to driving control of the arm unit 120. In the ideal joint control, a disturbance component such as friction or inertia in the joint unit 130 is estimated, and feedforward control is performed using the estimated disturbance component. Thus, even when there is a disturbance component such as friction, the ideal response can be implemented on driving of the joint unit 130. Thus, small influence of vibration or the like, high-accuracy responsiveness, and high positioning accuracy or stability are implemented in driving control of the arm unit 120.

Further, in the present embodiment, each of the plurality of joint units 130 configuring the arm unit 120 has a configuration suitable for the ideal joint control illustrated in FIG. 3, for example, and the rotational angle, the generated torque and the viscous drag coefficient of each of the joint units 130 can be controlled according to an electric current value. As described above, driving of each of the joint units 130 is controlled according to an electric current value, and driving of each of the joint units 130 is controlled according to the whole body cooperative control while detecting the entire state of the arm unit 120, and thus the counter balance is unnecessary, and the small robot arm apparatus 10 is implemented.

(6-2-5. Specific Example of Purpose of Motion)

Next, a specific example of the purpose of motion according to the present embodiment will be described. As described above in (6-2-4. Configuration of the robot arm control system), in the present embodiment, various kinds of purposes of motion are implemented by the whole body cooperative control. Here, as a specific example of the purpose of motion according to the present embodiment, the power assist movement and the pivot movement will be described. In the following description of the specific example of the purpose of motion, components of the robot arm control system according to the present embodiment are indicated using reference numerals in the functional block diagram illustrated in FIG. 11.

The power assist movement is a movement of controlling the state of the joint unit 130 such that gravity acting on the arm unit 120 is negated and controlling the state of the joint unit 130 such that movement of the arm unit 120 in a direction of force applied from the outside is supported. Specifically, when the user manually moves the arm unit 120, the power assist movement is a movement of controlling driving of the arm unit 120 such that force applied by the user is supported. More specifically, in order to implement the power assist movement, first, external torque is detected by the torque detecting unit 134 in a state in which no force other than gravity acts on the arm unit 120, and the instantaneous purpose of motion is set so that the generated torque for negating the detected external torque is generated by each of the joint units 130. At this stage, the position and posture of the arm unit 120 are held in a certain state. When external torque is further applied from the outside (for example, from the user) in this state, additionally applied external torque is detected by the torque detecting unit 134, and the instantaneous purpose of motion is further set such that each of the joint units 130 generates generated torque in the same direction as the detected additional external torque. As driving of each of the joint units 130 is controlled according to the instantaneous purpose of motion, the power assist movement is implemented. Through the power assist movement, the user can move the arm unit by small force, and thus the user can have a feeling of moving the arm unit 120 in a non-gravity state, and the operability of the arm unit 120 by the user is improved.

The pivot movement is a turning movement in which the front edge unit installed at the front edge of the arm unit 120 moves on a plane of a cone having a certain point in the space as an apex in a state in which a direction of the front edge unit is fixed on the certain point, and an axis of the cone is used as a pivot axis. Specifically, when the front edge unit is the imaging unit 140, the pivot movement is a turning movement in which the imaging unit 140 installed at the front edge of the arm unit 120 moves on a plane of a cone having a certain point in a space as an apex in a state in which the photographing direction of the imaging unit 140 is fixed on the certain point, and an axis of the cone is used as a pivot axis. As a point corresponding to the apex of the cone in the pivot movement, for example, the medical procedure part is selected. Further, in the pivot movement, the turning movement may be performed in a state in which a distance between the front edge unit or the imaging unit 140 and the point corresponding to the apex of the cone is maintained constant. Further, since the direction of the front edge unit or the photographing direction of the imaging unit 140 is fixed on a certain point (for example, the medical procedure part) in the space, the pivot movement is also referred to as a “point lock movement.”

The pivot movement will be described in further detail with reference to FIGS. 12 and 13. FIG. 12 is an explanatory diagram for describing the pivot movement that is a specific example of the arm movement according to an embodiment of the present disclosure. FIG. 13 is an explanatory diagram for describing the purpose of motion and the constraint condition for implementing the pivot movement illustrated in FIG. 12.

Referring to FIG. 12, a medical procedure part on a patient 750 is set as an apex in the pivot movement. The apex is referred to as a “pivot point P_(i).” In FIG. 12, for the sake of convenience, in the robot arm apparatus 10 according to the present embodiment, an imaging unit 713 serving as a unit corresponding to the imaging unit 140 of FIG. 11 is illustrated. As illustrated in FIG. 12, in the pivot movement, the purpose of motion and the constraint condition may be set so that the imaging unit 713 can move on a circumference of a bottom of a cone A, that is, the imaging unit 713 moves within a plane of the cone A in a state in which a distance between the imaging unit 713 and the pivot point P_(i) is maintained constant. Further, the shape of the cone A, that is, an angle θ of an apex of the cone A or a distance between the pivot point P_(i) and the imaging unit 713, may be appropriately set by the user. For example, the distance between the pivot point P_(i) and the imaging unit 713 is adjusted to a focal distance of an optical system in the imaging unit 713. As the pivot movement is applied, the medical procedure part can be observed at an equal distance at different angles, and thus convenience for the user who performs surgery can be improved.

Further, in the pivot movement, it is possible to move the position of the cone in which the imaging unit 713 is movable in a state in which the pivot point P_(i) is fixed as in the cones A and B. In the example illustrated in FIG. 12, the pivot axis of the cone A is substantially perpendicular to the medical procedure part, and the pivot axis of the cone B is substantially parallel to the medical procedure part. As described above, for example, the purpose of motion and the constraint condition may be set so that the cone for performing the pivot movement can be rotated by about 90° in a state in which the pivot point P_(i) is fixed such as the cones A and B. As the pivot movement is applied, it is possible to observe the medical procedure part from more directions, and thus the convenience for the user can be further improved.

The example illustrated in FIG. 12 illustrates an example in which the purpose of motion and the constraint condition are set so that the imaging unit 713 can move on the circumference of the bottom of the cone A, but the pivot movement according to the present embodiment is not limited to this example. For example, the purpose of motion and the constraint condition may be set so that the distance between the pivot point P_(i) and the imaging unit 713 can be freely changed in a state in which the position of the pivot point P_(i) and the angles θ of the apexes of the cones A and B are fixed. As the pivot movement is applied, it is possible to change the distance between the imaging unit 713 and the medical procedure part in a state in which the angle is fixed, and thus it is possible to observe the medical procedure part according to the user's desire, for example, to enlarge or reduce the medical procedure part and then observe the enlarged or reduced medical procedure part by appropriately adjusting the focal distance (focus) of the imaging unit 713.

Next, the purpose of motion and the constraint condition for implementing the pivot movement illustrated in FIG. 12 will be described in detail with reference to FIG. 13. Referring to FIG. 13, an example in which an arm unit 710 including the imaging unit 713 performs the pivot movement using the pivot point P_(i) as a base point. In FIG. 13, the pivot movement in which the distance between the imaging unit 713 and the pivot point P_(i) is maintained constant will be described as an example. The arm unit 710 includes a plurality of joint units 711 a, 711 b, and 711 c and a plurality of links 712 a, 712 b, and 712 c, and driving of the arm unit 710 is controlled according to the whole body cooperative control and the ideal joint control according to the present embodiment. For example, the arm unit 710 and the components thereof have the same configurations as the arm unit 420 and the components according to the present embodiment illustrated in FIG. 8.

Here, an arm coordinate system in which an origin O_(A) serving as a supporting point of the arm unit 710 is used as a zero point and a space coordinate system in which an origin O_(S) in a space is used as a zero point are considered. The motion of the arm unit 710 is managed by the arm coordinate system. Further, the arm coordinate system and the space coordinate system are defined such that they can be converted into each other.

An imaging center viewed from the space coordinate system is indicated by P_(w). Further, in the arm coordinate system, a position away from the joint unit 711 c connecting the imaging unit 713 with the link 712 c by a length D of the imaging unit 713 and a focal distance f of the imaging unit 713 is referred to as a pivot point P_(i).

In this state, the purpose of motion and the constraint condition are set so that the arm unit 710 is driven in a state in which the pivot point P_(i) matches the imaging center P_(w). In other words, the constraint of fixing the pivot point P_(i) in the arm coordinate system is fixed to the imaging center P_(w) in the space coordinate system is set in the arm coordinate system. Further, coordinates at which the imaging unit 713 is positioned on the plane of the cone having the pivot point P_(i) (that is, the imaging center P_(w)) as an apex or the position of the imaging unit 713 at which the imaging unit 713 faces the pivot point P_(i) is set as the purpose of motion. As the whole body cooperative control is performed under the constraint condition and the purpose of motion, even when the position and posture of the imaging unit 713 are changed by the movement of the arm unit 710, the direction of the imaging unit 713 consistently faces the imaging center P_(w) (that is, the pivot point P_(i)), and the distance between the imaging unit 713 and the imaging center P_(w) is maintained to have the focal distance f. Thus, the pivot movement in the state in which the distance between the imaging unit 713 and the imaging center P_(w) is maintained constant is implemented. When the pivot movement is performed while changing the distance between the imaging unit 713 and the imaging center P_(w) (or the pivot point P_(i)), it is desirable to change the setting method of the pivot point P_(i). Specifically, for example, in the arm coordinate system, it is desirable to set the position away from the joint unit 711 c by the length D of the imaging unit 713 and an arbitrary distance as the pivot point P_(i) and use the arbitrary distance a variable parameter.

Further, a combination of the pivot movement and the power assist movement may be used. When a combination of the pivot movement and the power assist movement is used, for example, when the user manually moves the imaging unit 140, the user can move the imaging unit 140 with small power due to a feeling of moving the imaging unit 140 in the non-gravity state, and the moving position of the imaging unit 140 is limited to within the plane of the cone. Thus, the movement operability of the imaging unit 140 is improved at the time of the pivot movement.

The power assist movement and the pivot movement have been described above as the specific example of the purpose of motion according to the present embodiment. The purpose of motion according to the present embodiment is not limited to this example. In the present embodiment, for example, the following purpose of motion can also be implemented.

For example, coordinates of the imaging unit 140 may be set as the purpose of motion so that the position of the imaging unit 140 is fixed at a certain position. In this case, for example, when force is applied from the outside to the components other than the imaging unit 140 of the arm unit 120, it is possible to set the purpose of motion and the constraint condition so that the joint unit 130 and the link are also fixed at a certain position and not moved, and it is possible to set the purpose of motion and the constraint condition so that the joint unit 130 and the link are moved according to the applied external force, but the position of the imaging unit 140 is fixed. In the latter case, for example, when the arm unit 120 interferes with a task and is desired to be moved, control of a high degree of freedom of moving the positions and postures of the other components of the arm unit 120 in the state in which an image captured by the imaging unit 140 is fixed is implemented.

Further, the purpose of motion and the constraint condition may be set so that a movement of stopping driving of the arm unit 120 immediately is implemented, for example, when the arm unit 120 detects contact with a person or a thing while being driven. By performing such a movement, it is possible to reduce a risk of the arm unit 120 colliding with a person or object. Further, when the arm unit 120 comes into contact with a person or object, for example, the joint state detecting unit 132 may detect the contact according to a change in the external torque applied to the joint unit 130.

Further, for example, the purpose of motion may be set so that the imaging unit 140 moves along a certain trajectory in the space. Specifically, coordinates of points indicating the certain trajectory may be set as the purpose of motion. By setting the purpose of motion as described above, the movable range of the imaging unit 140 is limited to the trajectory. Further, by setting the speed of the imaging unit 140, times at which the imaging unit 140 passes through the points, or the like as the purpose of motion together with the coordinates of the points indicating the trajectory, automated driving by which the imaging unit 140 automatically moves along a certain trajectory at a certain timing can also be performed. The driving control according to such a motion setting is effective, for example, when the robot arm apparatus 10 repeatedly performs a certain task automatically.

Further, for example, the purpose of motion and the constraint condition may be set so that a movement of preventing the arm unit 120 from invading a certain region in the space is implemented. As described above with reference to FIG. 7, in the present embodiment, the user performs surgery while viewing the display screen. Thus, if the arm unit 120 is positioned in a region between the user and the display screen, the user's field of vision is blocked, and thus the surgery efficiency is likely to be lowered. Thus, for example, by setting the region between the user and the display screen as an invasion prohibition region of the arm unit 120, the surgery efficiency can be improved.

Here, when the invasion prohibition region is set to the arm unit 120 as described above, it is preferable that the degrees of freedom of the arm unit 120 be more than the 6 degrees of freedom. This is because degrees of freedom after the 6 degrees of freedom can be used as redundant degrees of freedom, and thus it is possible to secure driving of the 6 degrees of freedom while dealing with the invasion prohibition region or the like. A configuration of a robot arm apparatus including an arm unit having more degrees of freedom than the 6 degrees of freedom will be described in detail with reference to FIG. 14.

FIG. 14 is a schematic diagram illustrating an external appearance of a modified example having a redundant degree of freedom in a robot arm apparatus according to an embodiment of the present disclosure. The same coordinate axes as the directions defined in FIG. 8 are illustrated in FIG. 14.

Referring to FIG. 14, a robot arm apparatus 450 according to the present modified example includes a base unit 460 and an arm unit 470. Further, the arm unit 470 includes a plurality of joint units 471 a to 471 g, a plurality of links 472 a to 472 d connecting the joint units 471 a to 471 g with one another, and an imaging unit 473 installed at the front edge of the arm unit 470. Here, the robot arm apparatus 450 illustrated in FIG. 14 corresponds to a configuration in which the degrees of freedom of the arm unit 470 are increased by one compared to the robot arm apparatus 400 described above with reference to FIG. 8. Thus, the functions and configurations of the base unit 460, each of the joint units 471 a to 471 g and the links 472 a to 472 d, and the imaging unit 473 are similar to the functions and configurations of the base unit 410, each of the joint units 421 a to 421 f and the links 422 a to 422 c, and the imaging unit 423 of the robot arm apparatus 400 described above with reference to FIG. 8, and thus a detailed description thereof is omitted. The following description will proceed focusing on a configuration of the arm unit 470 serving as a difference with the robot arm apparatus 400.

The robot arm apparatus 450 according to the present embodiment includes the 7 joint units 471 a to 471 g, and 7 degrees of freedom are implemented with regard to driving of the arm unit 470. Specifically, one end of the link 472 a is connected with the base unit 460, and the other end of the link 472 a is connected with one end of the link 472 b through the joint unit 421 a. Further, the other end of the link 422 b is connected with one end of the link 472 c through the joint units 471 b and 471 c. Furthermore, the other end of the link 472 c is connected with one end of the link 472 d through the joint units 471 d and 471 e, and the other end of 472 d is connected with the imaging unit 473 through the joint units 471 f and 471 g. As described above, the arm unit 470 extending from the base unit 460 is configured such that the base unit 460 serves as a support point, and the ends of the plurality of links 472 a to 472 d are connected with one another through the joint units 471 a to 471 g.

Further, as illustrated in FIG. 14, the joint units 471 a, 471 c, 471 e, and 471 g are installed such that the long axis direction of the links 472 b to 472 d connected thereto and the photographing direction of the imaging unit 473 connected thereto are set as the rotary axis direction, and the joint units 471 b, 471 d, and 471 f are installed such that the x axis direction serving as a direction in which connection angles of the links 472 c and 472 d and the imaging unit 473 connected thereto are changed within the y-z plane is set as the rotary axis direction. As described above, in the present modified example, the joint units 471 a, 471 c, 471 e, and 471 g have a function of performing yawing, and the joint units 471 b, 471 d, and 471 f have a function of performing pitching.

As the arm unit 470 has the above configuration, in the robot arm apparatus 450 according to the present embodiment, the 7 degrees of freedom are implemented with regard to driving of the arm unit 470, and thus it is possible to freely move the imaging unit 473 within the space in the movable range of the arm unit 470, and the redundant degree of freedom is provided. In FIG. 14, similarly to FIG. 8, a hemisphere is illustrated as an example of the movable range of the imaging unit 473. When the central point of the hemisphere is the photographing center of the medical procedure part photographed by the imaging unit 473, the medical procedure part can be photographed at various angles by moving the imaging unit 473 on the spherical surface of the hemisphere in a state in which the photographing center of the imaging unit 473 is fixed to the central point of the hemisphere. Since the robot arm apparatus 450 according to the present embodiment has one redundant degree of freedom, it is possible to limit the movement of the imaging unit 473 to the hemisphere and the trajectory of the arm unit 470, and it is also possible to easily deal with the constraint condition such as the invasion prohibition region. By setting the invasion prohibition region, for example, it is possible to control driving of the arm unit 470 so that the arm unit 470 is not positioned between the monitor on which the image captured by the imaging unit 473 is displayed and the practitioner or the staff, and it is possible to prevent the monitor from being blocked from the view of the practitioner and the staff. Further, as the invasion prohibition region is set, it is possible to control driving of the arm unit 470 so that the arm unit 470 moves while avoiding interference (contact) with the practitioner and the staff or any other device therearound.

(6-3. Processing Procedure of Robot Arm Control Method)

Next, a processing procedure of a robot arm control method according to an embodiment of the present disclosure will be described with reference to FIG. 15. FIG. 15 is a flowchart illustrating a processing procedure of a robot arm control method according to an embodiment of the present disclosure. The following description will proceed with an example in which the robot arm control method according to the present embodiment is implemented through the configuration of the robot arm control system 1 illustrated in FIG. 11. Thus, the robot arm control method according to the present embodiment may be a medical robot arm control method. Further, in the following description of the processing procedure of the robot arm control method according to the present embodiment, the functions of the respective components of the robot arm control system 1 illustrated in FIG. 11 have already been described above in (6-2-4. Configuration of the robot arm control system), and thus a detailed description thereof is omitted.

Referring to FIG. 15, in the robot arm control method according to the present embodiment, first, in step S801, the joint state detecting unit 132 detects the state of the joint unit 130. Here, the state of the joint unit 130 refers to, for example, the rotational angle, the generated torque and/or the external torque in the joint unit 130.

Then, in step S803, the arm state acquiring unit 241 acquires the arm state based on the state of the joint unit 130 detected in step S801. The arm state refers to a motion state of the arm unit 120, and may be, for example, a position, a speed, or acceleration of each component of the arm unit 120, or force acting on each component of the arm unit 120.

Then, in step S805, the operation condition setting unit 242 sets the purpose of motion and the constraint condition used for the operation in the whole body cooperative control based on the arm state acquired in step S803. Further, the operation condition setting unit 242 may not set the purpose of motion based on the arm state, may set the purpose of motion based on the instruction information on driving of the arm unit 120 which is input, for example, from the input unit 210 by the user, and may use the purpose of motion previously stored in the storage unit 220. Furthermore, the purpose of motion may be set by appropriately combining the above methods. Moreover, the operation condition setting unit 242 may use the constraint condition previously stored in the storage unit 220.

Then, in step S807, the operation for the whole body cooperative control using the generalized inverse dynamics is performed based on the arm state, the purpose of motion, and the constraint condition, and a control value Ta is calculated. The process performed in step S807 may be a series of processes in the virtual force calculating unit 243 and the actual force calculating unit 244 illustrated in FIG. 11, that is, a series of processes described above in (6-2-2. Generalized inverse dynamics).

Then, in step S809, the disturbance estimation value T _(d) is calculated, the operation for the ideal joint control is performed using the disturbance estimation value T _(d), and the command value T is calculated based on the control value T _(a). The process performed in step S809 may be a series of processes in the ideal joint control unit 250 illustrated in FIG. 11, that is, a series of processes described above in (6-2-3. Ideal joint control).

Lastly, in step S811, the drive control unit 111 controls driving of the joint unit 130 based on the command value T.

The processing procedure of the robot arm control method according to the present embodiment has been described above with reference to FIG. 15. In the present embodiment, the process of step S801 to step S811 illustrated in FIG. 15 is repeatedly performed while the task using the arm unit 120 is being performed. Thus, in the present embodiment, driving control of the arm unit 120 is continuously performed while the task using the arm unit 120 is being performed.

(6-4. Hardware Configuration)

Next, a hardware configuration of the robot arm apparatus 10 and the control device 20 according to the present embodiment illustrated in FIG. 11 will be described in detail with reference to FIG. 16. FIG. 16 is a functional block diagram illustrating an exemplary configuration of a hardware configuration of the robot arm apparatus 10 and the control device 20 according to an embodiment of the present disclosure.

The robot arm apparatus 10 and the control device 20 mainly include a CPU 901, a ROM 903, and a RAM 905. The robot arm apparatus 10 and the control device 20 further include a host bus 907, a bridge 909, an external bus 911, an interface 913, an input device 915, an output device 917, a storage device 919, a drive 921, a connection port 923, and a communication device 925.

The CPU 901 functions as an arithmetic processing device and a control device, and controls all or some operations of the robot arm apparatus 10 and the control device 20 according to various kinds of programs recorded in the ROM 903, the RAM 905, the storage device 919, or a removable storage medium 927. The ROM 903 stores a program, an operation parameter, or the like used by the CPU 901. The RAM 905 primarily stores a program used by the CPU 901, a parameter that appropriately changes in execution of a program, or the like. The above-mentioned components are connected with one another by the host bus 907 configured with an internal bus such as a CPU bus. The CPU 901 corresponds to, for example, the arm control unit 110 and the control unit 230 illustrated in FIG. 11 in the present embodiment.

The host bus 907 is connected to the external bus 911 such as a peripheral component interconnect/interface (PCI) bus through the bridge 909. Further, the input device 915, the output device 917, the storage device 919, the drive 921, the connection port 923, and the communication device 925 are connected to the external bus 911 via the interface 913.

The input device 915 is an operating unit used by the user such as a mouse, a keyboard, a touch panel, a button, a switch, a lever, or a pedal. For example, the input device 915 may be a remote control unit (a so-called remote controller) using infrared light or any other radio waves, and may be an external connection device 929 such as a mobile telephone or a PDA corresponding to an operation of the robot arm apparatus 10 and the control device 20. Further, for example, the input device 915 is configured with an input control circuit that generates an input signal based on information input by the user using the operating unit, and outputs the input signal to the CPU 901. The user of the robot arm apparatus 10 and the control device 20 can input various kinds of data to the robot arm apparatus 10 and the control device 20 or instruct the robot arm apparatus 10 and the control device 20 to perform a processing operation by operating the input device 915. For example, the input device 915 corresponds to the input unit 210 illustrated in FIG. 11 in the present embodiment. Further, in the present embodiment, the purpose of motion in driving of the arm unit 120 may be set by an operation input through the input device 915 by the user, and the whole body cooperative control may be performed according to the purpose of motion.

The output device 917 is configured with a device capable of visually or acoustically notifying the user of the acquired information. As such a device, there are a display device such as a CRT display device, a liquid crystal display device, a plasma display device, an EL display device or a lamp, an audio output device such as a speaker or a headphone, a printer device, and the like. For example, the output device 917 outputs a result obtained by various kinds of processes performed by the robot arm apparatus 10 and the control device 20. Specifically, the display device displays a result obtained by various kinds of processes performed by the robot arm apparatus 10 and the control device 20 in the form of text or an image. Meanwhile, the audio output device converts an audio signal including reproduced audio data, acoustic data, or the like into an analogue signal, and outputs the analogue signal. In the present embodiment, various kinds of information related to driving control of the arm unit 120 may be output from the output device 917 in all forms. For example, in driving control of the arm unit 120, the trajectory of movement of each component of the arm unit 120 may be displayed on the display screen of the output device 917 in the form of a graph. Further, for example, the display device 30 illustrated in FIG. 11 may be a device including the function and configuration of the output device 917 serving as the display device and a component such as a control unit for controlling driving of the display device.

The storage device 919 is a data storage device configured as an exemplary storage unit of the robot arm apparatus 10 and the control device 20. For example, the storage device 919 is configured with a magnetic storage unit device such as a hard disk drive (HDD), a semiconductor storage device, an optical storage device, a magneto optical storage device, or the like. The storage device 919 stores a program executed by the CPU 901, various kinds of data, and the like. For example, the storage device 919 corresponds to the storage unit 220 illustrated in FIG. 11 in the present embodiment. Further, in the present embodiment, the storage device 919 may store the operation condition (the purpose of motion and the constraint condition) in the operation related to the whole body cooperative control using the generalized inverse dynamics, and the robot arm apparatus 10 and the control device 20 may perform the operation related to the whole body cooperative control using the operation condition stored in the storage device 919.

The drive 921 is a recording medium reader/writer, and is equipped in or attached to the robot arm apparatus 10 and the control device 20. The drive 921 reads information stored in the removable storage medium 927 mounted thereon such as a magnetic disk, an optical disc, a magneto optical disc, or a semiconductor memory, and outputs the read information to the RAM 905. Further, the drive 921 can write a record in the removable storage medium 927 mounted thereon such as a magnetic disk, an optical disk, a magneto optical disk, or a semiconductor memory. For example, the removable storage medium 927 is a DVD medium, an HD-DVD medium, a Blu-ray (a registered trademark) medium, or the like. Further, the removable storage medium 927 may be a Compact Flash (CF) (a registered trademark), a flash memory, a Secure Digital (SD) memory card, or the like. Furthermore, for example, the removable storage medium 927 may be an integrated circuit (IC) card equipped with a non-contact type IC chip, an electronic device, or the like. In the present embodiment, various kinds of information related to driving control of the arm unit 120 is read from various kinds of removable storage media 927 or written in various kinds of removable storage media 927 through the drive 921.

The connection port 923 is a port for connecting a device directly with the robot arm apparatus 10 and the control device 20. As an example of the connection port 923, there are a Universal Serial Bus (USB) port, an IEEE1394 port, a Small Computer System Interface (SCSI) port, and the like. As another example of the connection port 923, there are an RS-232C port, an optical audio terminal, a High-Definition Multimedia Interface (HDMI) (a registered trademark), and the like. As the external connection device 929 is connected to the connection port 923, the robot arm apparatus 10 and the control device 20 acquire various kinds of data directly from the external connection device 929 or provide various kinds of data to the external connection device 929. In the present embodiment, various kinds of information related to driving control of the arm unit 120 may be read from various kinds of external connection devices 929 or written in various kinds of external connection devices 929 through the connection port 923.

For example, the communication device 925 is a communication interface configured with a communication device used for a connection with a communication network (network) 931. For example, the communication device 925 is a communication card for a wired or wireless local area network (LAN), Bluetooth (a registered trademark), or wireless USB (WUSB). Further, the communication device 925 may be an optical communication router, an asymmetric digital subscriber line (ADSL) router, various kinds of communication modems, or the like. For example, the communication device 925 can transmit or receive a signal to or from the Internet or another communication device, for example, according to a certain protocol such as TCP/IP. Further, the communication network 931 connected to the communication device 925 is configured with a network connected in a wired or wireless manner, and may be, for example, the Internet, a domestic LAN, infrared ray communication, radio wave communication, satellite communication, or the like. In the present embodiment, various kinds of information related to driving control of the arm unit 120 may be transmitted or received to or from an external device via the communication network 931 through the communication device 925.

The hardware configuration capable of implementing the functions of the robot arm apparatus 10 and the control device 20 according to an embodiment of the present disclosure has been described above. Each of the above components may be configured using a versatile member, and may be configured by hardware specialized for the function of each component. Thus, the hardware configuration to be used may be appropriately changed according to a technology level when the present embodiment is carried out. Further, although not illustrated in FIG. 16, the robot arm apparatus 10 obviously includes various kinds of components corresponding to the arm unit 120 illustrated in FIG. 11.

Further, it is possible to create a computer program for implementing the functions of the robot arm apparatus 10 according to the present embodiment, the control device 20, and the display device 30 and install the computer program in a personal computer or the like. Furthermore, it is possible to provide a computer readable recording medium storing the computer program as well. Examples of the recording medium include a magnetic disk, an optical disc, a magneto optical disc, and a flash memory. Further, for example, the computer program may be delivered via a network without using the recording medium.

(6-5. Summary of Medical Robot Arm Apparatus)

As described above, in the present embodiment, the following effects can be obtained.

As described above, according to the present embodiment, the arm unit 120 having the multi-link structure in the robot arm apparatus 10 has at least 6 or more degrees of freedom, and driving of each of the plurality of joint units 130 configuring the arm unit 120 is controlled by the drive control unit 111. Further, the medical apparatus is installed at the front edge of the arm unit 120. As driving of each joint unit 130 is controlled as described above, driving control of the arm unit 120 having a high degree of freedom is implemented, and the robot arm apparatus 10 for medical use having high operability for a user is implemented.

More specifically, according to the present embodiment, in the robot arm apparatus 10, the state of the joint unit 130 is detected by the joint state detecting unit 132. Further, in the control device 20, based on the state of the joint unit 130, the purpose of motion, and the constraint condition, various kinds of operations related to the whole body cooperative control using the generalized inverse dynamics for controlling driving of the arm unit 120 are performed, and torque command value T serving as the operation result are calculated. Furthermore, in the robot arm apparatus 10, driving of the arm unit 120 is controlled based on the torque command value T. As described above, in the present embodiment, driving of the arm unit 120 is controlled by the whole body cooperative control using the generalized inverse dynamics. Thus, driving control of the arm unit 120 according to the force control is implemented, and the robot arm apparatus having the high operability for the user is implemented. Further, in the present embodiment, in the whole body cooperative control, for example, control for implementing various kinds of purposes of motion for improving user convenience such as the pivot movement and the power assist movement can be performed. Furthermore, in the present embodiment, for example, various driving units for moving the arm unit 120 manually or through an operation input from a pedal are implemented, and thus user convenience is further improved.

Further, in the present embodiment, the whole body cooperative control and the ideal joint control are applied to driving control of the arm unit 120. In the ideal joint control, a disturbance component such as friction or inertia in the joint unit 130 is estimated, and feedforward control is performed using the estimated disturbance component. Thus, even when there is a disturbance component such as friction, the ideal response can be implemented on driving of the joint unit 130. Thus, small influence of vibration or the like, high-accuracy responsiveness, and high positioning accuracy or stability are implemented in driving control of the arm unit 120.

Further, in the present embodiment, each of the plurality of joint units 130 configuring the arm unit 120 has a configuration suitable for the ideal joint control illustrated in FIG. 3, for example, and the rotational angle, the generated torque and the viscous drag coefficient of each of the joint units 130 can be controlled according to an electric current value. As described above, driving of each of the joint units 130 is controlled according to an electric current value, and driving of each of the joint units 130 is controlled according to the whole body cooperative control while detecting the entire state of the arm unit 120, and thus the counter balance is unnecessary, and the small robot arm apparatus 10 is implemented.

As described above, according to the present embodiment, it is possible to fulfill all capabilities necessary for the robot arm apparatus described above in (6-1. Review of medical robot arm apparatus). Thus, it is possible to perform various kinds of medical procedures more efficiently using the robot arm apparatus according to the present embodiment and further reduce the fatigue or the burden of the user or the patient.

Further, in the present embodiment, as the arm unit 120 of the robot arm apparatus 10 is driven by the force control, even when the arm unit 120 interferes with or comes into contact with the practitioner, the staff, or the like during driving, the arm unit 120 does not generate larger force than necessary, and the arm unit 120 safely stops. Furthermore, when the interference is resolved, the arm unit 120 is moved up to a desired position according to the set purpose of motion, and the medical procedure is continued. As described above, in the present embodiment, as the force control is used for driving control of the robot arm apparatus 10, higher safety is secured even when the arm unit 120 interferes with something nearby while being driven.

For example, the above embodiment has shown an example in which a front edge unit of an arm unit of a robot arm apparatus is an imaging unit, and a medical procedure part is photographed by the imaging unit during surgery as illustrated in FIG. 7, but the present embodiment is not limited to this example. The robot arm control system 1 according to the present embodiment can be applied even when a robot arm apparatus including a different front edge unit is used for another purpose. For example, the front edge unit may be an endoscope or a laparoscope, and may be any other examination device such as an ultrasonic examination apparatus or a gastrocamera.

For example, for a medical procedure using a gastrocamera, the gastrocamera is inserted into the patient's body, and various procedures are performed using separately inserted surgical tools, such as forceps and an electrosurgical instrument, while observing a picture captured by the gastrocamera. With such a medical procedure method, if the practitioner were able to operate the tools for the procedure directly while operating the gastrocamera with the robot arm, for example, it would be possible for a single person to perform the medical procedure, enabling more efficient medical procedures. However, with typical existing balance arms, from the perspective of operability, it is difficult for a single person to operate the surgical tools by hand and operate the gastrocamera with the robot arm simultaneously. Thus, existing methods require multiple staff members, and it is typical to have one practitioner operate the gastrocamera with the robot arm while another practitioner performs the procedure using surgical tools. However, with a robot arm apparatus according to the present embodiment, high operability by whole body cooperative control is realized, as discussed above. In addition, by ideal joint control, high-precision response and high stability with fewer effects such as vibration are realized. Consequently, according to the present embodiment, it becomes possible for a single practitioner to easily operate a gastrocamera for observation with the robot arm apparatus and also operate surgical tools by hand.

Further, the robot arm apparatus according to the present embodiment may be used for purposes other than medical uses. In the robot arm apparatus according to the present embodiment, since the high-accuracy responsiveness and the high stability are implemented through the ideal joint control, for example, it is also possible to deal with a task such as processing or assembly of industrial components that has to be performed with a high degree of accuracy.

Further, the above embodiment has been described in connection with the example in which the joint unit of the robot arm apparatus includes a rotation mechanism, and rotary driving of the rotation mechanism is controlled such that driving of the arm unit is controlled, but the present embodiment is not limited to this example. For example, in the robot arm apparatus according to the present embodiment, the link configuring the arm unit may have a mechanism that expands or contracts in an extension direction of the link (such as a hydraulic driving mechanism or a mechanism that drives a ball screw, for example), and the length of the link may be variable. When the length of the link is variable, for example, driving of the arm unit is controlled such that a desired purpose of motion is achieved by the whole body cooperative control in which expansion and contraction of the link is considered in addition to rotation in the joint unit.

Further, the above embodiment has been described in connection with the example in which the degrees of freedom of the arm unit in the robot arm apparatus are the 6 or more degrees of freedom, but the present embodiment is not limited to this example. Further, the description has proceeded with the example in which each of the plurality of joint units configuring the arm unit includes the actuator that supports the ideal joint control, but the present embodiment is not limited to this example. In the present embodiment, various purposes of motion can be set according to the purpose of the robot arm apparatus. Thus, as long as the set purpose of motion can be achieved, the arm unit may have fewer than 6 degrees of freedom, and some of the plurality of joint units configuring the arm unit may be joint units having a general joint mechanism. As described above, in the present embodiment, the arm unit may be configured to be able to achieve the purpose of motion or may be appropriately configured according to the purpose of the robot arm apparatus.

7. Supplement

The preferred embodiments of the present disclosure have been described above with reference to the accompanying drawings, whilst the present disclosure is not limited to the above examples, of course. A person skilled in the art may find various alterations and modifications within the scope of the appended claims, and it should be understood that they will naturally come under the technical scope of the present disclosure.

In addition, the effects described in the present specification are merely illustrative and demonstrative, and not limitative. In other words, the technology according to the present disclosure can exhibit other effects that are evident to those skilled in the art along with or instead of the effects based on the present specification. Additionally, the present technology may also be configured as below.

(1)

An actuator including:

a reduction gear that reduces, by a certain reduction ratio, a rotational velocity of an input shaft joined to a rotary shaft of a motor, and transmits the reduced rotational velocity to an output shaft;

a first absolute angle encoder that detects a rotational angle of the input shaft; and

a second absolute angle encoder that detects a rotational angle of the output shaft.

(2)

The actuator according to (1), wherein

the rotational angle of the output shaft is detected based on the rotational angle of the input shaft detected by the first absolute angle encoder.

(3)

The actuator according to (1) or (2), wherein

a cumulative rotation count of the output shaft is computed based on the rotational angle of the output shaft detected by the second absolute angle encoder, and

the rotational angle of the output shaft is detected by adding the rotational angle of the input shaft detected by the first absolute angle encoder to a cumulative rotational angle of the input shaft computed from the cumulative rotation count.

(4)

The actuator according to (3), wherein

the cumulative rotation count of the input shaft is corrected based on the rotational angle of the input shaft estimated from a detection value of the rotational angle of the output shaft by the second absolute angle encoder.

(5)

The actuator according to (3), wherein

a rotational angle detection accuracy of the second absolute angle encoder is less than the rotational angle of the output shaft corresponding to one full rotation of the input shaft according to the reduction ratio of the reduction gear.

(6)

The actuator according to (1) or (2), further including:

a counter that holds a rotation count of the input shaft, wherein the rotational angle of the output shaft is detected by adding the rotational angle of the input shaft detected by the first absolute angle encoder to a cumulative rotational angle of the input shaft computed based on a value of the counter.

(7)

The actuator according to any one of (1) to (6), wherein

a failure of the actuator is detected based on a relationship between a detection value of the rotational angle of the input shaft from the first absolute angle encoder, and a detection value of the rotational angle of the output shaft from the second absolute angle encoder.

(8)

The actuator according to (7), wherein

a failure of at least one of the motor, the reduction gear, the first absolute angle encoder, and the second absolute angle encoder is output based additionally on change over time in the detection value of the rotational angle of the input shaft from the first absolute angle encoder and the detection value of the rotational angle of the output shaft from the second absolute angle encoder.

(9)

The actuator according to any one of (1) to (8), wherein

the motor is a brushless motor, and

the first absolute angle encoder also functions as a sensor that detects a rotation of a rotor of the motor.

(10)

The actuator according to anyone of (1) to (9), wherein

the first absolute angle encoder and the second absolute angle encoder are magnetic encoders that use a plurality of magnetic sensors to detect changes in a magnetic field due to a rotation of a magnet in a state in which the changes are phase-shifted by a certain amount, and thereby detect a rotational angle of the magnet.

(11)

A robot arm apparatus including:

an arm unit made up of a plurality of links joined by a plurality of a joint unit; and

a driving control unit that controls driving of an actuator provided in at least one of the joint unit based on a state of the joint unit, wherein

the actuator includes

-   -   a reduction gear that reduces, by a certain reduction ratio, a         rotational velocity of an input shaft joined to a rotary shaft         of a motor, and transmits the reduced rotational velocity to an         output shaft,     -   a first absolute angle encoder that detects a rotational angle         of the input shaft, and     -   a second absolute angle encoder that detects a rotational angle         of the output shaft.

(12)

The robot arm apparatus according to (11), wherein

the rotational angle of the output shaft is detected based on the rotational angle of the input shaft detected by the first absolute angle encoder.

(13)

The robot arm apparatus according to (11) or (12), wherein

a cumulative rotation count of the output shaft is computed based on the rotational angle of the output shaft detected by the second absolute angle encoder, and

the rotational angle of the output shaft is detected by adding the rotational angle of the input shaft detected by the first absolute angle encoder to a cumulative rotational angle of the input shaft computed from the cumulative rotation count.

(14)

The robot arm apparatus according to (13), wherein

the cumulative rotation count of the input shaft is corrected based on the rotational angle of the input shaft estimated from a detection value of the rotational angle of the output shaft by the second absolute angle encoder.

(15)

The robot arm apparatus according to (13), wherein

a rotational angle detection accuracy of the second absolute angle encoder is less than the rotational angle of the output shaft corresponding to one full rotation of the input shaft according to the reduction ratio of the reduction gear.

(16)

The robot arm apparatus according to (11) or (12), further including:

a counter that holds a rotation count of the input shaft, wherein

the rotational angle of the output shaft is detected by adding the rotational angle of the input shaft detected by the first absolute angle encoder to a cumulative rotational angle of the input shaft computed based on a value of the counter.

(17)

The robot arm apparatus according to any one of (11) to (16), wherein

a failure of the actuator is detected based on a relationship between a detection value of the rotational angle of the input shaft from the first absolute angle encoder, and a detection value of the rotational angle of the output shaft from the second absolute angle encoder.

(18)

The robot arm apparatus according to (17), wherein

a failure of at least one of the motor, the reduction gear, the first absolute angle encoder, and the second absolute angle encoder is output based additionally on change over time in the detection value of the rotational angle of the input shaft from the first absolute angle encoder and the detection value of the rotational angle of the output shaft from the second absolute angle encoder.

(19)

The robot arm apparatus according to any one of (11) to (18), wherein the motor is a brushless motor, and

the first absolute angle encoder also functions as a sensor that detects a rotation of a rotor of the motor to drive the motor.

(20)

The robot arm apparatus according to any one of (11) to (19), wherein

the first absolute angle encoder and the second absolute angle encoder are magnetic encoders that use a plurality of magnetic sensors to detect changes in a magnetic field due to a rotation of a magnet in a state in which the detected changes are phase-shifted by a certain amount, and thereby detect a rotational angle of the magnet.

(21)

The robot arm apparatus according to any one of (11) to (20), wherein

the arm unit is provided with a mounting unit on which is mounted a tool that performs a certain procedure.

(22)

The robot arm apparatus according to (21), wherein

the tool is a tool for medical use.

REFERENCE SIGNS LIST

-   1 robot arm control system -   3 rotational angle detection system -   10 robot arm apparatus -   20 control device -   30 display device -   110 arm control unit -   111 drive control unit -   120 arm unit -   130 joint unit -   131 joint driving unit -   132 rotational angle detecting unit -   133 torque detecting unit -   140 imaging unit -   210 input unit -   220 storage unit -   230 control unit -   240 whole body cooperative control unit -   241 arm state acquiring unit -   242 operation condition setting unit -   243 virtual force calculating unit -   244 actual force calculating unit -   250 ideal joint control unit -   251 disturbance estimating unit -   252 command value calculating unit -   300 actuator -   310 motor (brushless motor) -   320 reduction gear -   330 encoder (input shaft encoder, absolute angle encoder) -   340 encoder (output shaft encoder, absolute angle encoder) -   350 output shaft -   360 housing -   370 control unit -   371 output shaft angle information acquisition unit -   372 motor cumulative rotation count computation unit -   373 input shaft angle information acquisition unit -   374 input shaft cumulative operation angle computation unit -   375 output shaft angle computation unit 

The invention claimed is:
 1. A control apparatus, comprising: circuitry configured to: acquire a first detection value representing an absolute rotation angle of an input shaft coupled to a rotary shaft of a motor of an actuator; acquire a second detection value representing an absolute rotation angle of an output shaft coupled to the rotary shaft of the motor of the actuator; and detect a fault of the actuator based on: variation in at least one of the acquired first detection value or the acquired second detection value, and a relationship between the acquired first detection value and the acquired second detection value, wherein the relationship is based on a reduction ratio of a reduction gear coupled to the input shaft and the output shaft.
 2. The control apparatus according to claim 1, wherein the reduction ratio is read from a memory.
 3. The control apparatus according to claim 1, wherein the relationship is a non-proportional relationship.
 4. The control apparatus according to claim 1, wherein the circuitry is further configured to calculate a first rotation angle of the output shaft based on an error associated with the acquired first detection value.
 5. The control apparatus according to claim 4, wherein the circuitry is further configured to: calculate a cumulative rotational angle of the input shaft based on the error associated with the acquired first detection value; and calculate the first rotation angle of the output shaft based on the calculated cumulative rotational angle and the acquired second detection value.
 6. The control apparatus according to claim 5, wherein the circuitry is further configured to: calculate a second rotation angle of the output shaft based on the acquired second detection value; calculate a cumulative rotation count of the input shaft based on the calculated second rotation angle of the output shaft; calculate the cumulative rotational angle of the input shaft based on the calculated cumulative rotation count; and calculate the first rotation angle of the output shaft based on addition of a first rotation angle of the input shaft to the calculated cumulative rotational angle of the input shaft.
 7. The control apparatus according to claim 6, wherein the circuitry is further configured to: calculate a second rotation angle of the input shaft based on the second rotation angle of the output shaft; and correct the calculated cumulative rotation count based on the calculated second rotation angle of the input shaft.
 8. The control apparatus according to claim 7, further comprising: a counter configured to store a rotation count of the input shaft, wherein the circuitry is further configured to: calculate the cumulative rotational angle of the input shaft based on a value of the stored rotation count; and calculate the first rotation angle of the output shaft based on addition of the first rotation angle of the input shaft with the calculated cumulative rotational angle of the input shaft.
 9. The control apparatus according to claim 8, wherein the circuitry is further configured to: acquire the first detection value from a first absolute angle encoder; and acquire the second detection value from a second absolute angle encoder.
 10. The control apparatus according to claim 1, wherein the circuitry is further configured to calculate a rotation angle of the output shaft based on the acquired first detection value and the acquired second detection value.
 11. A robot arm, comprising: an arm including a plurality of links joined by at least one joint; and a driving control apparatus including circuitry, wherein the driving control apparatus is configured to: control, based on a state of the at least one joint, a motor of an actuator included in the at least one joint, wherein the actuator includes: a reduction gear configured to: reduce, by a reduction ratio, a rotational velocity of an input shaft joined to a rotary shaft of the motor; and transmit the reduced rotational velocity to an output shaft of the motor; and an absolute angle encoder configured to: detect a rotation angle of the input shaft; and detect a rotation angle of the output shaft, and wherein the circuitry is configured to: acquire a first detection value representing the rotation angle of the input shaft coupled to the rotary shaft of the motor; acquire a second detection value representing the rotation angle of the output shaft coupled to the rotary shaft of the motor; and detect a fault of the actuator based on: variation in at least one of the acquired first detection value or the acquired second detection value, and a relationship between the acquired first detection value and the acquired second detection value, wherein the relationship is based on the reduction ratio. 